REAR DOOR REASSEMBLY

Tech Tips


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

  • The procedure listed below is for the LH side.

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


  1. INSTALL REAR DOOR WEATHERSTRIP LH

    Tech Tips

    When installing the rear door weatherstrip, heat the vehicle body and rear door weatherstrip using a heat light.

    Standard
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Rear Door Weatherstrip 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or rear door weatherstrip excessively.


    1. w/ Spot Cover:


      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.

      4. Using a heat light, heat the vehicle body and a new rear door weatherstrip LH.

      5. Remove the peeling paper from the face of the rear door weatherstrip LH.

        Tech Tips

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

      6. Attach the 21 clips to install a new rear door weatherstrip LH.

        Tech Tips


        • If clips are damaged during installation, replace them.

        • Press the rear door weatherstrip LH firmly to install it.

    2. w/o Spot Cover:


      1. Attach the 21 clips to install the rear door weatherstrip LH.

        Tech Tips

        If clips are damaged during installation, replace them.

  2. INSTALL REAR DOOR CHECK ASSEMBLY LH


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

    2. 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 }

    3. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the bolt.

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

  3. INSTALL REAR DOOR CHECK COVER LH (w/ Cover)


    1. A015DLW

      Install the rear door check cover LH.

  4. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Entry and Start System)


    1. Install the door electrical key oscillator with the screw.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  5. INSTALL NO. 4 ELECTRICAL KEY WIRE HARNESS (w/ Entry and Start System)


    1. Connect the connector.

    2. Attach the 2 clamps to install the No. 4 electrical key wire harness to the rear door outside handle frame sub-assembly LH.

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


    1. A01562D

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

    2. Attach the 2 claws to install the rear door outside handle frame sub-assembly LH.

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

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

    4. w/ Entry and Start System:


      1. Attach the clamp.

  7. INSTALL REAR NO. 2 DOOR OUTSIDE HANDLE PAD LH


    1. Attach the 2 claws to install the rear No. 2 door outside handle pad LH.

  8. INSTALL REAR NO. 1 DOOR OUTSIDE HANDLE PAD LH


    1. Attach the 3 claws to install the rear No. 1 door outside handle pad LH.

  9. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A015A0Y

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

      Note

      If the bellcrank lever is not pulled and held when installing the rear door outside handle assembly LH, the bellcrank lever will interfere with the rear door outside handle assembly LH and the release plate may be damaged

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

    3. Using a T30 ''TORX'' socket, tighten the screw.

    4. w/ Entry and Start System:


      1. Connect the connector.

  10. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. Attach the claw to install the rear door outside handle cover LH.

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

  11. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. A015745E03
      Text in Illustration
      *A w/o Double Lock
      *B w/ Double Lock

      Install the rear door inside locking cable assembly LH.

    2. A01596W

      Attach the 3 claws.

  12. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the rear door lock remote control cable assembly LH.

    2. A0155I2

      Attach the claw.

  13. INSTALL REAR DOOR LOCK ASSEMBLY LH


    1. A01579O

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

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

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

    4. Using a T30 ''TORX'' wrench, the 3 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  14. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH

  15. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH


    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 surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new window frame moulding.


      1. Using a heat light, heat a new window frame moulding and the vehicle body surface.

      2. Remove the peeling paper from the face of the window frame moulding.

        Tech Tips

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

      3. A015D75E02

        Attach the clip and double-sided tape to install the window frame moulding.

        Tech Tips

        Press the window frame moulding firmly to install it.

  16. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH

    A0158XC

    1. Attach the claw to install the belt moulding.

  17. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY LH


    1. Apply MP grease to the sliding and rotating areas of the regulator motor.

    2. Using a T25 "TORX" driver, install the motor with the 3 screws.

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

      Tech Tips

      A new rear window regulator motor uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  18. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. A015C6NE04
      Text in Illustration
      *1 Temporary Bolt

      Apply MP grease to the sliding parts of the rear door window regulator sub-assembly LH.

    2. Loosely install the temporary bolt onto the rear door window regulator sub-assembly LH.

    3. Insert the rear door window regulator sub-assembly LH into the door panel. Use the temporary bolt to hang the rear door window regulator sub-assembly LH on the door panel.

      Note

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

    4. Temporarily install the rear door window regulator sub-assembly LH with the 3 bolts.

    5. Tighten the 4 bolts in the order shown in the illustration.

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

  19. INSTALL REAR NO. 2 DOOR FRAME GARNISH LH


    1. Attach a new clip to install the rear No. 2 door frame garnish LH.

  20. INSTALL REAR DOOR FRAME GARNISH LH


    1. Attach a new clip to install the rear door frame garnish LH.

  21. INSTALL REAR DOOR GLASS CHANNEL FILLER (for Tempered Glass)


    1. A0156Q4E02
      Text in Illustration
      *a Front Side
      *b 8.0 mm (0.327 in.)

      Install the rear door glass channel filler onto the rear door glass.

  22. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH (for Tempered Glass)


    1. Apply soapy water to the inside of the rear door glass channel sub-assembly LH.

    2. A0156XKE02
      Text in Illustration
      *a Front Side
      *b 8.0 mm (0.327 in.)

      Using a plastic-faced hammer, tap the channel onto the glass to install the rear door glass channel sub-assembly LH.

      Note

      Be careful not to damage the glass or rear door glass channel sub-assembly LH.

  23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. A01572Z

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

  24. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


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

  25. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. A0158VK

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

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


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

  27. INSTALL REAR DOOR GLASS RUN LH


    1. Install the rear door glass run LH.

  28. INSTALL REAR DOOR PANEL PROTECTOR LH


    1. Attach the claw to install the rear door panel protector LH.

  29. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. Apply butyl tape to the door.

    2. A015AG6

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

      Note


      • When installing the rear door service hole cover LH, pull the links and connectors through the rear door service hole cover LH.

      • There should be no wrinkles or folds after attaching the rear door service hole cover LH.

      • After attaching the rear door service hole cover LH, check the sealing quality.

    3. Connect the 2 connectors.

    4. Attach the 6 clamps.

    5. A015BL3E01

      Install the bolt as shown in the illustration.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  30. INSTALL REAR SPEAKER SET (w/ Rear Speaker)


    1. A0155P1

      Temporarily install the speaker by attaching the claw of the speaker to the door panel.

    2. Install the speaker with the 3 screws.

      Note

      Do not touch the cone part of the speaker.

    3. Connect the connector.

  31. INSTALL REAR NO. 3 SPEAKER ASSEMBLY (for 14 Speakers)


    1. A015AYKE01

      Align the speaker to the door position pins labeled A.

    2. Install the speaker with the 2 screws.

      Note

      Do not touch the cone part of the speaker.

    3. Attach the clamp and connect the connector.

  32. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH


    1. Install the rear door inside handle bezel LH to the trim board with the 6 screws.

  33. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the 2 claws to install the rear door inside handle sub-assembly LH.

  34. INSTALL REAR INNER DOOR GLASS WEATHERSTRIP LH


    1. A015905E02

      Install the rear inner door glass weatherstrip LH to the door panel.

  35. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect the connector.

    2. A0157I9

      Connect the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH to the rear door inside handle sub-assembly LH.

    3. A015D8Q

      Attach the 4 claws and 9 clips to install the rear door trim board sub-assembly LH.

    4. Install the 3 screws.

  36. INSTALL ASSIST GRIP COVER LH


    1. Attach the 9 claws to install the assist grip cover LH to the rear door trim board sub-assembly LH.

  37. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY


    1. A015DPX

      Attach the 2 claws to install the regulator switch.

  38. INSTALL REAR DOOR UPPER ARMREST BASE PANEL LH


    1. Connect the connector.

    2. A01561H

      Attach the 7 claws to install the armrest base panel.

  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH


    1. Attach the 4 claws to install the rear door inside handle bezel LH.

  40. INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)


    1. A015B9E

      Connect the connector.

    2. Attach the claw of the courtesy light to the rear door trim.

  41. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH


    1. Attach the 3 clamps and 7 clips to install the rear door outside moulding sub-assembly LH.

  42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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