REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   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. Click here

   REPAIR INSTRUCTION

   Click here

3. Click here

   INSTALL FRONT INNER BLACK OUT TAPE

   Click here

4. Click here

   INSTALL REAR INNER BLACK OUT TAPE

   Click here

5. Click here

   INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

   Click here

6. Click here

   INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

   Click here

7. Click here

   INSTALL REAR DOOR NO. 3 WEATHERSTRIP

   
   

   1. Clean the rear door panel.

   2. 

      Install a new rear door No. 3 weatherstrip.

      Table 1. Text in Illustration

      *1	Double-sided Tape

8. Click here

   INSTALL REAR DOOR BELT MOULDING ASSEMBLY

   Click here

9. Click here

   INSTALL CURTAIN HOOK (w/ Rear Door Sunshade)

   
   
   1. 

      Engage the 4 claws and install the 2 curtain hooks.

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

10. Click here

    INSTALL REAR DOOR PANEL CUSHION

    
    
    1. 

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

11. Click here

    INSTALL REAR DOOR NO. 2 WEATHERSTRIP

    
    
    1. 

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

12. Click here

    INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY

    
    
    1. 

       Engage the 2 guides.

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

13. Click here

    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. 

       Engage the claw.

       Table 2. Text in Illustration

       *a	Outside
       *b	Inside

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

       4.0 N*m

       41 kgf*cm

       35 in.*lbf

    4. 

       Engage the clamp.

14. Click here

    INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

    
    
    1. 

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

15. Click here

    INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

    
    
    1. 

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

16. Click here

    INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

    
    
    1. 

       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. 

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

    4. 

       Connect the connector.

    5. Engage the 2 claws.

17. Click here

    INSTALL REAR DOOR OUTSIDE HANDLE COVER

    
    
    1. 

       Engage the claw.

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

       4.0 N*m

       41 kgf*cm

       35 in.*lbf

18. Click here

    INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

    
    
    1. 

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

    2. 

       Engage the 3 claws as shown in the illustration.

19. Click here

    INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

    
    
    1. 

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

    2. 

       Engage the claw as shown in the illustration.

20. Click here

    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. 

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

    3. 

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

       Table 3. Text in Illustration

       *1	Release Plate

    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.

       5.5 N*m

       56 kgf*cm

       49 in.*lbf

21. Click here

    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. 

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

       5.4 N*m

       55 kgf*cm

       48 in.*lbf

       Tip:

       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. Click here

    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. 

       Temporarily install the rear door window regulator assembly.

       Table 4. Text in Illustration

       *1	Temporary Bolt

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

       11 N*m

       112 kgf*cm

       8 ft.*lbf

       Tip:

       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. Click here

    INSTALL REAR DOOR GLASS CHANNEL FILLER

    
    

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

    2. 

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

       Table 5. Text in Illustration

       *A	Front Side
       *B	Rear Side
       *a	Edge of curved surface

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

24. Click here

    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. 

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

       Table 6. Text in Illustration

       *A	Front Side
       *B	Rear Side
       *a	Edge of curved surface

       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. Click here

    INSTALL REAR DOOR GLASS ASSEMBLY

    
    
    1. 

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

26. Click here

    INSTALL REAR DOOR QUARTER WINDOW GLASS

    
    

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

    2. 

       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. Click here

    INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY

    
    
    1. 

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

       Bolt
       8.5 N*m	87 kgf*cm	75 in.*lbf

28. Click here

    INSTALL REAR DOOR NO. 1 VENT SEAL

    
    
    1. 

       Install the rear door No. 1 vent seal.

29. Click here

    INSTALL REAR DOOR GLASS RUN

    
    
    1. 

       Install the rear door glass run.

30. Click here

    INSTALL REAR DOOR FRAME GARNISH

    
    
    1. 

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

31. Click here

    INSTALL REAR DOOR WEATHERSTRIP

    
    

    1. Clean the rear door panel.

    2. 

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

       Table 7. Text in Illustration

       *1	Double-sided Tape

32. Click here

    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. 

       Install the rear door check assembly with the 3 bolts.

       Table 8. Text in Illustration

       *1	Bolt (A)
       *2	Bolt (B)

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

33. Click here

    INSTALL REAR DOOR SERVICE HOLE COVER

    
    

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

    2. 

       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.

       Table 9. Text in Illustration

       *a	Reference Point

    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. Click here

    INSTALL REAR DOOR ARMREST SET BRACKET

    
    
    1. 

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

35. Click here

    INSTALL REAR SPEAKER ASSEMBLY

    Click here

36. Click here

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

    
    
    1. 

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

37. Click here

    INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

    
    
    1. 

       Install the rear door inner glass weatherstrip.

38. Click here

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

    Click here

39. Click here

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

    
    
    1. 

       Engage the claw.

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

    3. 

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

    4. w/ Illumination:

       
       
       1. 

          Engage the 3 clamps.

40. Click here

    INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

    
    
    1. 

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

41. Click here

    INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

    
    
    1. 

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

       Table 10. Text in Illustration

       *a	Reference Point

    2. 

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

       Table 11. Text in Illustration

       *1	Rear Door Inside Locking Cable Assembly
       *2	Rear Door Lock Remote Control Cable Assembly

    3. w/ Illumination:

       
       

       1. Connect the connector.

    4. for 15 Speakers:

       
       

       1. Connect the connector.

    5. 

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

       Table 12. Text in Illustration

       *1	Reference Boss
       *2	Rear Door Inner Glass Weatherstrip

    6. 

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

    7. 

       Install the 3 screws.

42. Click here

    INSTALL COURTESY LIGHT ASSEMBLY

    Click here

43. Click here

    INSTALL REAR DOOR NO. 1 STIFFENER CUSHION

    
    
    1. 

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

44. Click here

    INSTALL DOOR PULL HANDLE COVER

    
    
    1. 

       Install the door pull handle cover.

45. Click here

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

    
    

    1. Connect the connector.

    2. 

       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. Click here

    INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

    
    
    1. 

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

47. Click here

    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. Click here

    INSTALL LUGGAGE TRIM SERVICE HOLE COVER

    Click here

49. Click here

    INITIALIZE POWER WINDOW CONTROL SYSTEM

    (Click here)

50. Click here

    INSPECT POWER WINDOW OPERATION

    (Click here)