REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • Use the same procedure for the RH and LH sides.

  • The procedure listed below is for the LH side.

  • A bolt without a torque specification is shown in the standard bolt chart.

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PROCEDURE


  1. REPAIR INSTRUCTION

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  2. INSTALL NO. 3 BLACK OUT TAPE LH

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  3. INSTALL NO. 2 BLACK OUT TAPE LH

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  4. INSTALL NO. 1 BLACK OUT TAPE LH

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  5. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING LH

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  6. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING LH

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  7. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH

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  8. INSTALL REAR DOOR NO. 3 WEATHERSTRIP LH

    Tech Tips

    When installing the rear door No. 3 weatherstrip LH, heat the rear door panel using a heat light.

    Standard
    Item Temperature
    Rear Door Panel 40 to 60°C (104 to 140°F)

    Note

    Do not heat the rear door panel and rear door No. 3 weatherstrip LH excessively.


    1. Clean the rear door panel surface.


      1. Using a heat light, heat the rear door panel surface.

      2. Remove the double-sided tape from the rear door panel surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new rear door No. 3 weatherstrip LH.


      1. Using a heat light, heat the rear door panel surface.

      2. Remove the peeling paper from the face of the rear door No. 3 weatherstrip LH.

        Tech Tips

        After removing the peeling paper, keep the exposed adhesive free from foreign matter.

      3. B002KG3

        Install the rear door No. 3 weatherstrip LH as shown in the illustration.

        Tech Tips

        Press the rear door No. 3 weatherstrip LH firmly to install it.

  9. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH

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  10. INSTALL OUTSIDE MOULDING RETAINER

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  11. INSTALL NO. 2 MOULDING TAPE

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  12. INSTALL REAR DOOR REAR OUTSIDE MOULDING PAD

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  13. INSTALL REAR DOOR NO. 1 MOULDING PAD

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  14. INSTALL REAR DOOR REAR UPPER OUTSIDE MOULDING LH

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  15. INSTALL REAR DOOR NO. 2 WEATHERSTRIP LH

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  16. INSTALL REAR DOOR UPPER OUTSIDE MOULDING PAD

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  17. INSTALL REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY LH

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  18. INSTALL REAR DOOR PANEL CUSHION


    1. Install the rear door panel cushion.

  19. INSTALL REAR DOOR FRAME GARNISH LH


    1. Install a new rear door frame garnish LH.

  20. INSTALL REAR DOOR WEATHERSTRIP LH


    1. Attach the 25 clips to install the rear door weatherstrip LH.

  21. INSTALL REAR DOOR CHECK ASSEMBLY LH


    1. Apply MP grease to the sliding area of the rear door check assembly LH.

    2. When reusing a bolt:


      1. Clean the threads of the bolt with non-residue solvent.

      2. Apply adhesive to the threads of the bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

    3. Install the rear door check assembly LH to the door panel with the 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Install the rear door check assembly LH to the body panel with the bolt.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  22. INSTALL DOOR OUTSIDE HANDLE BUSH


    1. Install the door outside handle bush.

  23. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding area of the rear door outside handle frame sub-assembly LH.

    2. B002H6S

      Temporarily install the rear door outside handle frame sub-assembly LH as shown in the illustration.

    3. Using a T30 "TORX" socket wrench, attach the claw and install the rear door outside handle frame sub-assembly LH with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  24. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. Attach the 3 claws to install the rear door front outside handle pad.

  25. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. Attach the 4 claws to install the rear door rear outside handle pad.

  26. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH

    B002KFL

    1. Using a T30 "TORX" socket wrench, install the rear door outside handle cover LH.

  27. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B002J25

      Temporarily install the rear door outside handle assembly LH in the direction of the arrow shown in the illustration.

    2. B002I8G

      Connect the 2 claws and install the holder to the rear door outside handle assembly LH.

    3. B002JV3

      Connect the 3 claws and install the connector and connector cover.

  28. INSTALL REAR DOOR LOCK ASSEMBLY LH

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  29. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER


    1. Install the rear door lock child protection cover.

  30. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding and rotating areas of the rear door window regulator sub-assembly LH.

    2. B002IVIC01
      *1 Temporarily Bolt

      Temporarily install the temporarily bolt to the rear door window regulator sub-assembly LH.

    3. Install the rear door window regulator sub-assembly LH with the 5 bolts, and then tighten the temporarily bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

      Note

      Be careful not to drop the rear door window regulator as it may become damaged.

  31. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. Temporarily install the power window regulator switch assembly with rear door armrest base panel.

    2. Connect the cable to the auxiliary battery negative (-) terminal.

    3. Move the rear door window regulator so that the rear door glass bolts can be seen.

    4. Disconnect the cable from the auxiliary battery negative (-) terminal.

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

      Click here

    5. B002HNB

      Insert the rear door glass sub-assembly LH as shown in the illustration.

      Note

      Do not damage the rear door glass sub-assembly.

    6. B002I6K

      Install the rear door glass sub-assembly LH to the rear door window regulator sub-assembly LH with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    7. Install the hole plug.

  32. INSTALL REAR DOOR REAR GUIDE SEAL LH


    1. B002HQ3C01
      B002HVY Screw
      B002I10 Attaching Direction

      Attach the rear door rear guide seal LH in the direction indicated by the arrow in the illustration.

    2. Lift up the weatherstrip and install the rear door rear guide seal LH with the 2 screws.

  33. INSTALL REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY LH


    1. B002JWAC02
      B002HVY Bolt
      B002I10 Screw

      Install the 2 screws.

    2. Install the 2 bolts to the rear door rear lower window frame sub-assembly LH.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  34. INSTALL REAR DOOR GLASS RUN LH


    1. Install the rear door glass run LH.

  35. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. Apply new butyl tape to the rear door panel.

    2. Pass each cable and connector through a new rear door service hole cover LH.

    3. Align the rear door service hole cover LH to the specified positions on the rear door panel sub-assembly and attach it.

      Tech Tips

      Securely install the front door service hole cover LH by attaching it without any wrinkles or air bubbles.

    4. Attach the clamp.

    5. w/ Rear Speaker:


      1. Attach the clamp.

    6. Connect the 2 connectors.

      B002JWPC02
      *A w/o Rear Speaker *B w/ Rear Speaker
      *a Reference Point - -

  36. INSTALL REAR DOOR NO. 2 SERVICE HOLE COVER (w/o Rear Speaker)


    1. Install the 3 bolts to the rear door No. 2 service hole cover.

  37. INSTALL REAR SPEAKER ASSEMBLY (w/ Rear Speaker)

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  38. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (w/ Rear Speaker)

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  39. INSTALL REAR DOOR ARMREST SET BRACKET LH


    1. Install the 2 screws to the rear door armrest set bracket LH.

  40. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. Install the rear door inner glass weatherstrip LH.

  41. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Install the 6 screws to the rear door inside handle sub-assembly LH.

  42. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH.

    2. Attach the 2 clamps.

    3. Attach the 8 clips to install the rear door trim board sub-assembly LH.

    4. w/ Rear Speaker:


      1. Connect the connector.

    5. B002JUFC02
      B002HVY Screw A
      B002I10 Screw B
      B002H26 Screw C

      Install the screw labeled A.

    6. Install the screw labeled B.

    7. Install the screw labeled C.

  43. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL


    1. Connect the connector.

    2. Attach the 4 claws, 2 clips to install the power window regulator switch assembly with rear door armrest base panel.

  44. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH


    1. Attach the 3 claws to install the rear door inside handle bezel plug LH.

  45. INSTALL REAR DOOR TRIM COVER LH


    1. Install the rear door trim cover LH.

  46. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here


    1. w/o Spare Tire:

      Detach the 2 claws and remove the battery service cover.

    2. Tighten the nut and connect the cable from to auxiliary battery negative (-) terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  47. INSTALL DECK FLOOR BOX LH (w/ Spare Tire)

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  48. INSTALL REAR DECK FLOOR BOX (w/ Spare Tire)

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  49. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY (w/ Spare Tire)

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  50. CHECK SRS WARNING LIGHT

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  51. PERFORM DIAGNOSTIC SYSTEM CHECK

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  52. INITIALIZE POWER WINDOW CONTROL SYSTEM

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  53. CHECK POWER WINDOW CONTROL SYSTEM

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