REAR DOOR REASSEMBLY

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

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

  • 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. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


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

      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 to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is higher than 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape 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 falls off easily. When the temperature is high, the tape loses elasticity.

    3. Before installation.


      1. Make sure any dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame) is removed, and that the surface is smooth. If the surface is rough 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 level.

        Note

        Do not bend the tape or leave it in a place with a high temperature.

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

      Note


      • Position the tape with a high level of accuracy to achieve a neat finish and to avoid peeling.

      • The tape cannot be reused because it deforms and will not fit 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 touch the vehicle body while applying the tape. Tilt the squeegee 40 to 50° (for pressing forward) or 30 to 45° (for pulling) from the vehicle body surface and press with a force of 20 to 30 N (2 to 3 kgf) while moving the squeegee at a constant slow speed of 3 to 7 cm (1.2 to 2.8 in.) per second.

        A0094SME02

        Note

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

        Tech Tips


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

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.393 to 0.787 in.) from the edge of the squeegee.

        Text in Illustration
        *A Pressing *B Pulling
        *1 Squeegee *2 Black Out Tape
        *3 Release Paper - -
        *a Sectional View *b Non-padded Side
        *c Padded Side - -
    6. A009AT2E02
      Text in Illustration
      *1 Squeegee
      *a First
      *b Second
      *c Third

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


      1. If it is difficult to press the tape, press 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 the installation of the tape (how to use a squeegee and the 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 to avoid wrinkles in the tape and 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, apply new tape.

        Note

        Do not reuse the tape.

  2. INSTALL REAR DOOR OUTSIDE STRIPE LH

    A0098IZE01

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

      Reference Value
      Area Specified Condition
      A +/-1.0 mm (0.039 in.) from End

  3. INSTALL BLACK OUT TAPE LH

    A0095Q7E01

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

      Reference Value
      Area Specified Condition
      A +/-1.0 mm (0.039 in.) from End

  4. INSTALL REAR DOOR LOWER OUTSIDE STRIPE LH

    A009BRNE01

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

      Reference Value
      Area Specified Condition
      A +/-1.0 mm (0.039 in.) from End

  5. INSTALL NO. 2 BLACK OUT TAPE LH

    A00970XE01

    1. Refer to the illustration to position a new No. 2 black out tape.

      Reference Value
      Area Specified Condition
      A 2 to 4 mm (0.078 to 0.158 in.)
      B 4 to 6 mm (0.157 to 0.236 in.)

  6. 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 rear door front window frame moulding.


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

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

        Tech Tips

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

      3. Attach the clip and double-sided tape to install the rear door front window frame moulding.

        Tech Tips

        Press the rear door front window frame moulding firmly to install it.

    3. Install a new door window frame moulding clip.

  7. INSTALL REAR DOOR BELT MOULDING LH


    1. Attach the 7 claws to install the rear door belt moulding.

  8. INSTALL REAR DOOR PANEL CUSHION


    1. Attach the clip to install a new door panel cushion.

  9. INSTALL REAR DOOR NO. 2 WEATHERSTRIP LH


    1. Attach the 6 clips and guide to install the rear door No. 2 weatherstrip.

  10. INSTALL REAR DOOR WEATHERSTRIP LH


    1. Attach the 19 clips and guide to install the rear door weatherstrip.

  11. INSTALL REAR DOOR CHECK ASSEMBLY LH


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

    2. A00O3CX

      Install the door check 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 door check to the body panel with the bolt.

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

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


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

    2. A00O98R

      Attach the door handle nut and 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 }

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


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

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


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

  15. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A00O8SE

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

      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.

    3. A00OBD7

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

  16. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


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

    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 }

  17. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the rear door inside locking cable assembly.

    2. Attach the 3 claws.

  18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


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

    2. Attach the claw.

  19. INSTALL REAR DOOR LOCK ASSEMBLY LH

    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 surface of the connector which contacts the door lock wiring harness seal.

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


    1. A0094ZWE01
      Text in Illustration
      *A w/o Double Locking System
      *B w/ Double Locking System
      A009BSG Slide

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

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

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

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

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

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

  20. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY LH


    1. Attach the 2 claws to install the rear power window regulator switch assembly.

  21. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY LH


    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. A00O7CIE02
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the rear door window regulator assembly with the temporary bolt.

    4. Temporarily install the 3 bolts, and then tighten the temporary bolt and 3 bolts.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

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

  22. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A00O5Q8E02
      Text in Illustration
      *a Front Side
      *b Rear Side

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

      Standard
      Area Specified Condition
      A 21 mm (0.827 in.)
      B 22.5 mm (0.886 in.)

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

  23. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH


    1. A00O94NE03
      Text in Illustration
      *a Front Side
      *b Rear Side

      Apply soapy water to a new rear door glass channel sub-assembly.

      Standard
      Area Specified Condition
      A 21 mm (0.827 in.)
      B 22.5 mm (0.886 in.)

      Note

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

    2. Install the rear door glass channel sub-assembly to the position shown in the illustration.

  24. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. Connect the cable to the negative (-) battery terminal and rear power window regulator motor connector.

    2. A00O8NO

      Connect the power window regulator switch assembly and move the arm of the regulator so that the roller on the arm can be seen through the service hole.

    3. Disconnect the power window regulator switch assembly and rear power window regulator motor connector.

    4. Disconnect the cable from the negative (-) battery terminal.

      Note


      • w/ Navigation System (for HDD):

        After the ignition switch is turned off, the HDD navigation system requires approximately a minute to record various types of memory and settings. As a result, after turning the ignition switch off, wait a minute or more before disconnecting the cable from the negative (-) battery terminal.

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

    5. A00O9RJ

      Insert the rear door glass sub-assembly into the rear door panel along the rear door glass run as indicated by the arrow in the illustration.

  25. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


    1. A00O5SL

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

  26. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. A00O7UA

      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 FRAME GARNISH LH


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

  28. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH


    1. Insert the rear door window division bar sub-assembly from above.

    2. Install the rear door window division bar sub-assembly to the glass run.

    3. Install the temporary bolt to the rear door window division bar sub-assembly.

    4. Install the rear door window division bar sub-assembly.

    5. Install the 2 bolts and screw.

    6. Tighten the temporary bolt to install the rear door window division bar sub-assembly.

  29. INSTALL REAR DOOR GLASS RUN LH


    1. Install the glass run.

  30. INSTALL REAR DOOR SERVICE HOLE COVER


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

    2. A00O364E01
      Text in Illustration
      *1 Reference Point

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

    3. Attach the rear door service hole cover using to the reference points on the rear door panel.

      Note


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

      • After attaching the service hole cover, check the seal quality.

    4. Connect the connector.

    5. Attach the 2 clamps to the rear door wire.

  31. INSTALL REAR SPEAKER SET


    1. A00JZU7E01

      Temporarily install the speaker by attaching the 2 claws of the speaker to the door panel.

    2. Install the rear speaker set with the 3 screws in the order shown in the illustration.

      Note

      Do not touch the cone of the speaker.

    3. Connect the connector.

  32. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. A00OADE

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

    2. Install the 2 screws.

    3. A00O2YQ

      Install the 8 screws to the rear door armrest.

  33. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 14 Speakers)


    1. A00JX4EE01

      Align the speaker with the door position pins labeled A.

    2. Install the rear No. 2 speaker with the 2 screws.

      Note

      Do not touch the cone of the speaker.

  34. INSTALL NO. 2 INTERIOR ILLUMINATION LIGHT SUB-ASSEMBLY


    1. A0097CN

      Turn the light in the direction indicated by the arrow to install it.

    2. Attach the clamp.

    3. Connect the connector.

  35. INSTALL REAR DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH


    1. A0096A9

      Connect the connector.

    2. Attach the claw to install the light.

  36. INSTALL REAR DOOR COURTESY LIGHT ASSEMBLY LH


    1. Connect the connector.

    2. Attach the 2 claws to install the light.

  37. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY


    1. Attach the 2 claws to install the rear power window regulator switch assembly.

  38. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. A00O6BR

      Attach the 3 claws to install the rear door inner glass weatherstrip as shown in the illustration.

  39. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. A00O32D

      Install the clamp to the door panel.

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

    3. Connect each connector.

    4. A00O5NC

      Attach the rear door trim board sub-assembly by attaching the 4 claws of the rear door inner glass weatherstrip as shown in the illustration.

    5. Attach the 9 clips and install the rear door trim board sub-assembly.

    6. Install the 3 screws.

  40. INSTALL ASSIST GRIP COVER LH


    1. A00OBDH

      Attach the 8 claws to install the assist grip cover.

  41. INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL LH


    1. A00O3XZ

      Attach the 3 claws to install the door inside handle bezel.

  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.

  43. INITIALIZE POWER WINDOW CONTROL SYSTEM


    1. Initialize the power window control system Click here.