REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The following procedure is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  2. REPAIR INSTRUCTION (w/ Black Out Tape)

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  3. INSTALL REAR DOOR UPPER OUTSIDE STRIPE (w/ Black Out Tape)

    Click here

  4. INSTALL REAR DOOR OUTSIDE STRIPE (w/ Black Out Tape)

    Click here

  5. INSTALL REAR DOOR LOWER OUTSIDE STRIPE (w/ Black Out Tape)

    Click here

  6. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

    Click here

  7. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

    Click here

  8. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  9. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  10. INSTALL REAR DOOR NO. 3 WEATHERSTRIP


    1. Clean the rear door panel.

    2. Remove the release paper from a new rear door No. 3 weatherstrip.

      Tech Tips

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

    3. B006J50C01
      B006IOI Double-sided Tape

      Engage the claw and install the rear door No. 3 weatherstrip.

  11. INSTALL REAR DOOR DUST PROOF SEAL


    1. B006I9S

      Engage the 3 claws to install 3 new rear door dust proof seals.

  12. INSTALL REAR DOOR PANEL CUSHION


    1. B006ITA

      Engage the 2 claws to install a new rear door panel cushion.

  13. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. B006HGTC01
      *A Outside
      *B Inside

      Engage the claw as shown in the illustration.

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

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

  14. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B006HX2

      Engage the 3 guides and claw to install the rear door rear outside handle pad.

  15. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B006IZB

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

  16. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. B006IJX

      Engage the claw.

    2. Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw.

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

  17. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. B006IRHC01
      B006IFV Install in this Direction

      Insert the front end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly.

    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly, then slide the rear door outside handle assembly toward the front of the vehicle to install it.

    3. B006IUH

      Move the lever as shown in the illustration and engage the 2 claws to secure the rear door outside handle assembly.

  18. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

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  19. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY


    1. Apply MP grease to the sliding parts of the rear door window regulator assembly.

    2. Temporarily install the temporary bolt to the rear door window regulator assembly.

    3. B006HJLC01
      *a Temporary Bolt

      Temporarily install the rear door window regulator assembly with the 3 bolts.

    4. Tighten the temporary bolt and 3 bolts to install the rear door window regulator assembly.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

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

    5. Connect the connector.

  20. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. Apply soapy water to a new rear door glass channel filler.

    2. B006HR2C01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Install the rear door glass channel filler to the rear door glass sub-assembly at position shown in the illustration.

      Standard Dimension
      Area Measurement
      A 5.0 mm (0.197 in.)
      B 5.0 mm (0.197 in.)

  21. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY


    1. Apply soapy water to the channel filler side of the rear door glass channel sub-assembly.

    2. B006IVCC01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Using a plastic hammer, install the rear door glass channel sub-assembly to the position shown in the illustration.

      Standard Dimension
      Area Measurement
      A 5.0 mm (0.197 in.)
      B 5.0 mm (0.197 in.)

      Note

      To prevent damaging the rear door glass sub-assembly, be careful not to strike the channel with too much force.

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. B006J9QC01
      B006IFV Install in this Direction (1)
      B006IV0 Install in this Direction (2)

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

      Note

      Do not damage the rear door glass sub-assembly.

    2. B006IFR

      Slide the rear door glass sub-assembly to install it as shown in the illustration.

  23. INSTALL REAR DOOR QUARTER WINDOW GLASS


    1. Install the rear door quarter window glass to the rear door quarter window weatherstrip.

    2. B006IN4C01
      B006IFV Install in this Direction

      Install the rear door quarter window glass with rear door quarter window weatherstrip as shown in the illustration.

  24. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY


    1. B006HZJC01
      B006IR6 Screw
      B006IKP Bolt

      Install the rear door window division bar sub-assembly with the screw and 2 bolts.

      Torque:
      Screw
      3.1 N*m  { 32 kgf*cm, 27 in.*lbf }
      Bolt
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  25. INSTALL REAR DOOR WEATHERSTRIP


    1. Clean the rear door panel.

    2. Remove the release paper from a new rear door weatherstrip.

      Tech Tips

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

    3. B006HDBC01
      *a Double-sided Tape

      Engage the 25 clips and install the rear door weatherstrip.

  26. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole in the vehicle body.

    3. Clean the threads of the bolt (B).

    4. Apply adhesive to the threads of the bolt (B).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. B006I9KN01

      Install the rear door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      Bolt (B)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  27. INSTALL REAR DOOR GLASS RUN


    1. B006ILD

      Install the rear door glass run.

  28. INSTALL REAR DOOR NO. 2 SERVICE HOLE COVER


    1. B006HQN

      Install the rear door No. 2 service hole cover.

  29. INSTALL REAR DOOR PANEL PROTECTOR


    1. B006J83

      Install the rear door panel protector.

  30. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. B006HLDC01
      *a Reference Point

      Pass the rear door lock remote control cable assembly and rear door inside locking cable assembly through a new rear door service hole cover.

    3. Attach the rear door service hole cover according to the reference points on the rear door panel.

      Note

      Securely install the rear door service hole cover preventing wrinkles and air bubbles.

  31. INSTALL REAR DOOR FRAME GARNISH


    1. B006I38

      Engage the 2 claws to install the rear door frame garnish.

  32. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  33. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B006HTY

      Engage the 2 claws to install the rear door inside handle sub-assembly.

  34. INSTALL REAR DOOR NO. 2 VENT SEAL


    1. B006J04C01
      B006IFV Install in this Direction

      Install the rear door No. 2 vent seal to the front door inner glass weatherstrip.

  35. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP WITH REAR DOOR NO. 2 VENT SEAL


    1. B006HA2C01
      B006IFV Install in this Direction

      Install the rear door inner glass weatherstrip with rear door No. 2 vent seal as shown in the illustration.

  36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. B006HD1C01
      B006IFV Install in this Direction

      Install the No. 1 door scuff plate clamp as shown in the illustration.

    2. B006JA7C01
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly
      B006IFV Install in this Direction

      Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly to the rear door inside handle sub-assembly as shown in the illustration.

    3. B006I5F

      Engage the 6 claws and guide.

    4. Engage the 8 clips to install the rear door trim board sub-assembly.

    5. B006HOZ

      Install the 3 screws.

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


    1. Connect the connector.

    2. B006ISRC01
      B006IFV Install in this Direction

      Engage the 2 clips and 2 claws to install the rear power window regulator switch assembly with rear door upper armrest base panel as shown in the illustration.

  38. INSTALL REAR ARMREST ASSEMBLY


    1. B006J9GC01
      B006IFV Install in this Direction

      Engage the 3 clips and 7 claws to install the rear armrest assembly as shown in the illustration.

  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. B006IDQ

      Engage the 3 claws to install the rear door inside handle bezel plug.

  40. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

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  41. INITIALIZE POWER WINDOW CONTROL SYSTEM

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  42. INSPECT POWER WINDOW OPERATION

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