REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure described below 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 auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work Click here.

  2. REPAIR INSTRUCTION

    Click here

  3. INSTALL FRONT INNER BLACK OUT TAPE

    Click here

  4. INSTALL REAR INNER BLACK OUT TAPE

    Click here

  5. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

    Click here

  6. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  7. INSTALL REAR DOOR NO. 3 WEATHERSTRIP


    1. Clean the rear door panel.

    2. A0007C4E07
      Text in Illustration
      *1 Double-sided Tape

      Install a new rear door No. 3 weatherstrip.

  8. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  9. INSTALL CURTAIN HOOK (w/ Rear Door Sunshade)


    1. A0005NW

      Engage the 4 claws and install the 2 curtain hooks.

    2. Engage the 2 pins as shown in the illustration.

  10. INSTALL REAR DOOR PANEL CUSHION


    1. A0007OE

      Engage the claw to install a new rear door panel cushion.

  11. INSTALL REAR DOOR NO. 2 WEATHERSTRIP


    1. A0004XM

      Engage the 5 clips to install the rear door No. 2 weatherstrip.

  12. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY


    1. A0007HK

      Engage the 2 guides.

    2. Install the rear door inside panel reinforce sub-assembly with the 3 screws.

  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. A0009LCE04
      Text in Illustration
      *a Outside
      *b Inside

      Engage the claw.

    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 }
    4. A000412

      Engage the clamp.

  14. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A0008HY

      Engage the 2 claws to install the rear door rear outside handle pad.

  15. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A0005UV

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

  16. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A0005M8

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

      Note

      If the bellcrank lever is not pulled and held when installing the outside handle sub-assembly, the bellcrank lever will interfere with the outside handle and the release plate will be damaged.

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

    3. A000918

      Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

    4. A000692

      Connect the connector.

    5. Engage the 2 claws.

  17. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A0009QM

      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 }

  18. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A0009FZ

      Install the rear door inside locking cable assembly as shown in the illustration.

    2. A0003WZ

      Engage the 3 claws as shown in the illustration.

  19. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A0005M2

      Install the rear door lock remote control cable assembly as shown in the illustration.

    2. A00085C

      Engage the claw as shown in the illustration.

  20. INSTALL REAR DOOR LOCK ASSEMBLY

    Note


    • When reusing the removed rear door lock assembly, replace the door lock wiring harness seal on the connector with a new one.

    • Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.

    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock assembly.


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

    2. When reusing the rear door lock assembly:


      1. A00067L

        Install a new door lock wiring harness seal to the rear door lock assembly.

    3. A0003T2E04
      Text in Illustration
      *1 Release Plate

      Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.

    4. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.

    5. Using a T30 "TORX" socket wrench, install the rear door lock assembly with the 3 screws.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  21. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.


    1. A0006NE

      Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.

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

      Tech Tips

      When replacing the rear window regulator, a new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  22. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY


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

    2. Install the temporary bolt to the rear door window regulator assembly.

    3. A0009NPE03
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the rear door window regulator assembly.

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

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    5. Connect the connector.

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

    7. Connect the rear power window regulator switch assembly.

    8. Operate the rear power window regulator switch assembly to lower the rear door window regulator assembly to the lowest position.

    9. Disconnect the rear power window regulator switch assembly.

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

  23. INSTALL REAR DOOR GLASS CHANNEL FILLER


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

    2. A00094BE01
      Text in Illustration
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Install the rear door glass channel filler to the position shown in the illustration.

      Standard Dimension
      Area Measurement
      A 10.0 mm (0.394 in.)
      B 10.0 mm (0.394 in.)

  24. 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. A0008P0E01
      Text in Illustration
      *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 15.0 mm (0.591 in.)
      B 14.2 mm (0.559 in.)

      Note

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

  25. INSTALL REAR DOOR GLASS ASSEMBLY


    1. A0003F9

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

  26. INSTALL REAR DOOR QUARTER WINDOW GLASS


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

    2. A00063S

      Install the rear door quarter window glass together with the rear door quarter window weatherstrip in the direction indicated by the arrow in the illustration.

  27. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. A0003VN

      Install the rear door lower window frame sub-assembly with the screw and 2 bolts.

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

  28. INSTALL REAR DOOR NO. 1 VENT SEAL


    1. A00043J

      Install the rear door No. 1 vent seal.

  29. INSTALL REAR DOOR GLASS RUN


    1. A0009BO

      Install the rear door glass run.

  30. INSTALL REAR DOOR FRAME GARNISH


    1. A0008SF

      Engage the 3 claws to install the rear door frame garnish.

  31. INSTALL REAR DOOR WEATHERSTRIP


    1. Clean the rear door panel.

    2. A0003Q7E01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 22 clips and guide to install a new rear door weatherstrip.

  32. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A00091HE07
      Text in Illustration
      *1 Bolt (A)
      *2 Bolt (B)

      Install the rear door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Bolt (B)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  33. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. A0004B1E04
      Text in Illustration
      *a Reference Point

      Pass the rear door lock remote control cable assembly, rear door inside locking cable assembly and each connector 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.

    4. Engage the 2 clamps.

    5. Connect the connector.

  34. INSTALL REAR DOOR ARMREST SET BRACKET


    1. A0006CG

      Install the rear door armrest set bracket with the 2 screws.

  35. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  36. INSTALL REAR SIDE CURTAIN ASSEMBLY (w/ Rear Door Sunshade)


    1. A0003FM

      Engage the 2 claws and 2 clips and install the rear side curtain assembly.

  37. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A00068G

      Install the rear door inner glass weatherstrip.

  38. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 15 Speakers)

    Click here

  39. INSTALL REAR DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel and Bamboo Panel)


    1. A0008PR

      Engage the claw.

    2. Install the rear door trim ornament sub-assembly with the screw.

    3. A0008G8

      Install the rear door trim ornament assembly with the 11 screws.

    4. w/ Illumination:


      1. A00055G

        Engage the 3 clamps.

  40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A0007EE

      Engage the 2 guides and claw to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

  41. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A0005I0E04
      Text in Illustration
      *a Reference Point

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

    2. A0004SME04
      Text in Illustration
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly

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

    3. w/ Illumination:


      1. Connect the connector.

    4. for 15 Speakers:


      1. Connect the connector.

    5. A0004G7E01
      Text in Illustration
      *1 Reference Boss
      *2 Rear Door Inner Glass Weatherstrip

      Engage the rear door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

    6. A0003JI

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

    7. A0008AQ

      Install the 3 screws.

  42. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  43. INSTALL REAR DOOR NO. 1 STIFFENER CUSHION


    1. A0004WL

      Install the rear door No. 1 stiffener cushion with the screw.

  44. INSTALL DOOR PULL HANDLE COVER


    1. A0006VP

      Install the door pull handle cover.

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


    1. Connect the connector.

    2. A0004ZP

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

  46. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A00067G

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

  47. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  48. INSTALL LUGGAGE TRIM SERVICE HOLE COVER

    Click here

  49. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  50. INSPECT POWER WINDOW OPERATION

    Click here