REAR DOOR REASSEMBLY

Tech Tips


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

  • The procedure described below is for the LH side.


  1. PRECAUTION

    Note

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

  2. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


      1. Using a heat light, heat the vehicle body surface.

        Heating Temperature
        Item Temperature
        Vehicle Body 40 to 60°C (104 to 140°F)

        Note

        Do not heat the vehicle body excessively.

      2. Wipe off any tape adhesive residue with cleaner.

    2. Installation temperature


      1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.

        Tech Tips


        • The most appropriate temperature for installing the tape is 25°C (77°F).

        • When the temperature is low, the tape becomes stiff and comes off easily. When the temperature is high, the tape elasticity increases.

    3. Before installation


      1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.

        Tech Tips

        Spray water on the shop floor to settle any dust.

    4. Key points for handling the tape


      1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.

        Note

        Do not bend the tape or leave it in high temperature places.

    5. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)

      Note


      • Position the tape accurately to achieve a neat finish and to avoid peeling.

      • The tape cannot be reused because it deforms after removal.


      1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not contact the vehicle body prematurely. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 3 to 7 cm (1.18 to 2.76 in.) per second.

        A01G7AKE02
        Text in Illustration
        *A Pressing Forward *B Pulling
        *1 Non-padded Side *2 Padded Side
        *3 Squeegee *4 Black Out Tape
        *5 Release Paper - -
        *a Side View - -
        Reference Measurement
        Area Measurement
        A 10 to 20 mm (0.394 to 0.787 in.)
        B 30 to 70 mm/sec. (1.18 to 2.76 in./sec.)
        C 40 to 50° (for pressing forward)
        D 30 to 45° (for pulling)

        Note

        Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

        Tech Tips


        • Either angle of the squeegee (pressing forward or pulling) is acceptable.

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.

    6. Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces)


      1. A01G7MGE09
        Text in Illustration
        *1 Squeegee
        *2 Hem
        *a First
        *b Second
        *c Third

        If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.

        Tech Tips

        When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

    7. Key points for installation of the tape (how to use a squeegee and installation procedure for corners)


      1. Remove the release paper and apply the tape carefully with your fingers.

      2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.

    8. Check after installation


      1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.

        Note

        Do not reuse the tape.

  3. INSTALL FRONT INNER BLACK OUT TAPE


    1. Refer to the illustration to position a new front inner black out tape.

      A01G91WE01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Straight
      *c Triangle - -
      Standard Measurement
      Dimension Measurement
      A 1.5 mm (0.0591 in.)
      B 1.0 mm (0.0394 in.)

    2. Remove the release paper and apply the front inner black out tape.

  4. INSTALL REAR INNER BLACK OUT TAPE


    1. Refer to the illustration to position a new rear inner black out tape.

      A01G5A9E01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Straight
      *c Triangle - -
      Standard Measurement
      Dimension Measurement
      A 1.5 mm (0.0591 in.)
      B 1.0 mm (0.0394 in.)

    2. Remove the release paper and apply the rear inner black out tape.

  5. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY


    1. Engage the guide and claw of the rear door window frame moulding sub-assembly to the door frame.

      A01G8ZU

    2. Using an air riveter or hand riveter with a nose piece, install the rear door window frame moulding sub-assembly with 8 new rivets.

      Tech Tips

      If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

      Note


      • A01G4VSE09

        Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

        Text in Illustration
        *1 Riveter
        *2 Mandrel
        *a Incorrect
      • A01G8EGE10

        Confirm that the rivets are seated properly against the moulding.

        Text in Illustration
        *1 Riveter
        *a Incorrect

      • Do not tilt the riveter when installing the rivet to the moulding.

      • Do not leave any clearance between the rivet head and moulding.

      • A01G8IGE12

        Do not leave any clearance between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

        Text in Illustration
        *1 Riveter
        *a Incorrect

  6. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Tech Tips

    When installing a new rear door front window frame moulding, heat the vehicle body and rear door front window frame moulding using a heat light.

    Heating Temperature
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or rear door front window frame moulding excessively.


    1. Clean the vehicle body surface.


      1. Using a heat light, heat the vehicle body surface.

      2. Remove the double-sided tape from the vehicle body.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new rear door front window frame moulding.


      1. Using a heat light, heat the vehicle body and rear door front window frame moulding.

      2. Remove the release paper from the rear door front window frame moulding.

        Tech Tips

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

      3. A01G702E01
        Text in Illustration
        *1 Double-sided Tape
        *2 Caulking Sponge

        Engage the guide and clip and install a new rear door front window frame moulding.

  7. INSTALL REAR DOOR NO. 3 WEATHERSTRIP


    1. Clean the rear door panel.

    2. A01G9MIE01
      Text in Illustration
      *1 Double-sided Tape

      Install a new rear door No. 3 weatherstrip.

  8. INSTALL REAR DOOR BELT MOULDING ASSEMBLY


    1. A01G6S4

      Engage the guide and 6 claws to install the rear door belt moulding assembly as shown in the illustration.

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


    1. A01G5NG

      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. A01G5AL

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

  11. INSTALL REAR DOOR NO. 2 WEATHERSTRIP


    1. A01G806

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

  12. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY


    1. A01G6BS

      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. A01G55QE01
      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. A01G4YK

      Engage the clamp.

  14. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A01G5WQ

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

  15. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A01G5UH

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

  16. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A01G5LZ

      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. A01G4P9

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

    4. A01G7U8

      Connect the connector.

    5. Engage the 2 claws.

  17. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A01G5FX

      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. A01G9RF

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

    2. A01G980

      Engage the 3 claws as shown in the illustration.

  19. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A01G4ZZ

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

    2. A01G893

      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. A01G89I

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

    3. A01G6B3E01
      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. A01G6R4

      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. A01G5A5E01
      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 negative (-) battery 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 negative (-) battery terminal.

  23. INSTALL REAR DOOR GLASS CHANNEL FILLER


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

    2. A01G65ME01
      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. A01G5RZE01
      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. A01G7VL

      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. A01G5TJ

      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. A01G78T

      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. A01G613

      Install the rear door No. 1 vent seal.

  29. INSTALL REAR DOOR GLASS RUN


    1. A01G808

      Install the rear door glass run.

  30. INSTALL REAR DOOR FRAME GARNISH


    1. A01G830

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

  31. INSTALL REAR DOOR WEATHERSTRIP


    1. Clean the rear door panel.

    2. A01G5BME01
      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. A01G4ZOE02
      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. A01G6CNE01
      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. A01G4PX

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

  35. INSTALL REAR SPEAKER ASSEMBLY


    1. Install the rear speaker assembly with the 3 screws.

      Note

      Do not touch the speaker cone.

    2. Connect the connector.

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


    1. A01G617

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

  37. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A01G955

      Install the rear door inner glass weatherstrip.

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


    1. Engage the 3 claws to install the rear No. 2 speaker assembly.

      Note

      Do not touch the speaker cone.

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


    1. A01G9QP

      Engage the claw.

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

    3. A01G4AX

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

    4. w/ Illumination:


      1. A01G7RS

        Engage the 3 clamps.

  40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01G51L

      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. A01G5TOE01
      Text in Illustration
      *a Reference Point

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

    2. A01G5MFE01
      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. A01G787E01
      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. A01G9NA

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

    7. A01G5FU

      Install the 3 screws.

  42. INSTALL COURTESY LIGHT ASSEMBLY


    1. Connect the connector.

    2. A01G657E01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Engage the claw to install the courtesy light assembly.

  43. INSTALL REAR DOOR NO. 1 STIFFENER CUSHION


    1. A01G5KG

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

  44. INSTALL DOOR PULL HANDLE COVER


    1. A01G8OX

      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. A01G72N

      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. A01G7ES

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

  47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  48. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  49. INSPECT POWER WINDOW OPERATION

    Click here