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. 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 turns 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 and will not fit any more after being removed.

      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 touch the vehicle body while applying the tape. 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 30 to 70 mm (1.18 to 2.76 in.) per second.

        A011RJCE02
        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 (0.393 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. 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.

        A011UIPE09
        Text in Illustration
        *1 Squeegee
        *2 Hem
        *a First
        *b Second
        *c Third

        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.

  2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

    1. Refer to the illustration to position a new rear door lower outside stripe.

      A011SYVE01
      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 stripe.

  3. INSTALL REAR DOOR OUTSIDE STRIPE

    1. Refer to the illustration to position a new rear door outside stripe.

      A011UMHE01
      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 stripe.

  4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

    1. Engage the guide of the rear door upper window frame moulding to the door frame.

      A011ROU

    2. Using an air riveter or hand riveter with a nose piece, install the rear door upper window frame moulding with 6 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

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

        A011TSFE09
        Text in Illustration
        *1 Riveter
        *2 Mandrel
        *a Incorrect

      • Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding.

        A011SIME10
        Text in Illustration
        *1 Riveter
        *a Incorrect

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

        A011UWLE12
        Text in Illustration
        *1 Riveter
        *a Incorrect

  5. 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.

      A011UWOE01
      Text in Illustration
      *1 Double-sided Tape
      *2 Caulking Sponge

      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. Install the rear door front window frame moulding with the clip.

  6. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

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

      A011RI1

  7. INSTALL REAR DOOR PANEL CUSHION

    1. Engage the 2 claws to install 2 new rear door panel cushions.

      A011SJ7

  8. INSTALL REAR DOOR NO. 2 WEATHERSTRIP

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

      A011UGT

  9. 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.

      A011U2VE01
      Text in Illustration
      *1 Door Handle Nut
      *a Outside
      *b Inside

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

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

  10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

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

      A011RAF

  11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

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

      A011R1W

  12. 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.

      A011QPE

      Note

      If the bellcrank lever is not pulled and held when installing the outside handle, 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. Next, slide the rear door outside handle assembly toward the front of the vehicle to install it.

  13. INSTALL REAR DOOR OUTSIDE HANDLE COVER

    1. Engage the claw and install the rear door outside handle cover.

      A011UZC

    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 }

  14. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

    1. Install the rear door inside locking cable assembly.

      A011SON

    2. Engage the 3 claws.

      A011SOQ

  15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

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

      A011T85

    2. Engage the claw.

      A011TFZ

  16. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

    Note

    • When reusing the removed rear door lock with motor 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 with motor assembly.

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

    2. When reusing the rear door lock with motor assembly:

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

        A011TPV

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

      A011T4EE01
      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 with motor assembly.

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

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

  17. 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.

      A011QOW
      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.

  18. 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.

      A011SD8E02
      Text in Illustration
      *1 Temporary Bolt

    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 }

  19. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY

    1. Engage the guide.

      A011QO1

    2. Install a new rear door inside panel reinforce sub-assembly with the 4 screws.

  20. INSTALL REAR DOOR FRAME GARNISH

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

      A011S12

  21. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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

      A011R2Y

  22. 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.

      A011TT5

  23. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY

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

      A011V10

  24. INSTALL REAR DOOR GLASS RUN

    1. Install the rear door glass run.

      A011UWH

  25. INSTALL REAR DOOR WEATHERSTRIP

    1. Engage the 20 clips to install the rear door weatherstrip.

      A011R57

  26. 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 2 nuts and bolt.

      A011SXY
      Torque:
      Bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  27. 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.

      A011RC6E01
      Text in Illustration
      *1 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. Connect the connector.

  28. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

    1. Install the rear door inner glass weatherstrip.

      A011S1G

  29. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

    1. Engage the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

      A011UKI

  30. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

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

      A011UP3

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

      A011TOJE01
      Text in Illustration
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly

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

      A011R1YE01
      Text in Illustration
      *1 Reference Boss

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

      A011U67

    5. Install the 3 screws.

    6. If protective tape has been applied, remove it.

  31. INSTALL REAR ARMREST ASSEMBLY

    1. Engage the 2 guides, 3 clips and 7 claws to install the rear armrest assembly.

      A011SYR

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

    1. Connect the connector.

    2. Engage the 4 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

      A011R9V

  33. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

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

      A011QNY

  34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  35. INSPECT POWER WINDOW OPERATION

    Click here