REAR DOOR INSTALLATION

Tech Tips


  • 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. INSTALL REAR DOOR NO. 2 WEATHERSTRIP LH


    1. Attach the 7 clips to install the rear door No. 2 weatherstrip.

  2. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING LH (for Wagon)


    1. Install a nose piece to an air riveter or hand riveter.

    2. Insert the mandrel part of a new rivet into the nose piece.

    3. Using the riveter, install the rear door rear window frame moulding as shown in the illustration.

      Tech Tips

      If the rivet cannot be cut, pull it once and cut it.

      A003EBS

      Note


      • A003ALIE02

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

      • A003EMHE02

        Confirm that the rivets are seated properly against the rear door rear window frame moulding.

      • Do not tilt the riveter when installing the rivet to the rear door rear window frame moulding.

      • Do not leave any space between the rivet head and rear door rear window frame moulding.

      • A003CRNE02

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

  3. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING LH (for Wagon)


    1. Install a nose piece to an air riveter or hand riveter.

    2. Insert the mandrel part of a new rivet into the nose piece.

    3. Using the riveter, install the rear door upper window frame moulding as shown in the illustration.

      Tech Tips

      If the rivet cannot be cut, pull it once and cut it.

      A003BH5

      Note


      • A003ALIE02

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

      • A003EMHE02

        Confirm that the rivets are seated properly against the rear door upper window frame moulding.

      • Do not tilt the riveter when installing the rivet to the rear door upper window frame moulding.

      • Do not leave any space between the rivet head and rear door upper window frame moulding.

      • A003CRNE02

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

  4. INSTALL REAR DOOR MOULDING SUB-ASSEMBLY OUTSIDE LH (for Sedan)


    1. Install a nose piece to an air riveter or hand riveter.

    2. Insert the mandrel part of a new rivet into the nose piece.

    3. Using the riveter, install the rear door moulding outside as shown in the illustration.

      Tech Tips

      If the rivet cannot be cut, pull it once and cut it.

      A003CRR

      Note


      • A003ALIE02

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

      • A003EMHE02

        Confirm that the rivets are seated properly against the rear door moulding outside.

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

      • Do not leave any space between the rivet head and rear door moulding outside.

      • A003CRNE02

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

  5. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY LH


    1. for Sedan:

      Install the rear door window frame moulding sub-assembly Click here.

    2. for Wagon:

      Install the rear door window frame moulding sub-assembly Click here.

  6. INSTALL REAR DOOR BELT MOULDING LH


    1. for Sedan:

      Install the rear door belt moulding LH Click here.

    2. for Wagon:

      Install the rear door belt moulding LH Click here.

  7. INSTALL REAR DOOR WEATHERSTRIP LH (for Sedan)


    1. Clean the door surface.


      1. Wipe off any tape adhesive residue with cleaner.

    2. If reusing the weatherstrip:

      Clean the weatherstrip:


      1. Remove the double-sided tape from the weatherstrip.

      2. Wipe off any tape adhesive residue with cleaner.

      3. A003CI9E01
        Standard
        Area Specified Condition
        *1 Length: 30 mm (1.18 in.)
        *2 Width: 5.0 mm (0.197 in.)
        *3 Thickness: 0.8 mm (0.0315 in.)

        Apply new double-sided tape to the weatherstrip, as shown in the illustration.

        Standard
        Area Specified Condition
        *1 Length: 30 mm (1.18 in.)
        *2 Width: 5.0 mm (0.197 in.)
        *3 Thickness: 0.8 mm (0.0315 in.)
    3. A003D0C
      Area Specified Condition
      *1 Length: 30 mm (1.18 in.)
      *2 Width: 5.0 mm (0.197 in.)
      *3 Thickness: 0.8 mm (0.0315 in.)

      Install the weatherstrip.


      1. Using a heat light, heat the door.

      2. Remove the peeling paper from the face of the weatherstrip.

        Tech Tips

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

      3. Attach the 19 clips to install the weatherstrip.

  8. INSTALL REAR DOOR WEATHERSTRIP LH (for Wagon)


    1. A003E4P

      Attach the 18 clips to install the weatherstrip.

  9. INSTALL REAR DOOR CHECK ASSEMBLY LH


    1. A003DGO

      Apply MP grease to the sliding areas of the door check.

    2. 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:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  10. INSTALL NO. 2 SEPARATOR DOOR STIFFENER CUSHION


    1. A003EP3

      Install the No. 2 separator door stiffener cushion to the body panel with the bolt.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  11. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY LH


    1. A003B0M

      Install the rear door inside panel reinforce sub-assembly to the door panel with the 4 bolts.

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


    1. A003E36

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

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

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

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

  13. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A003EC2

      Attach the 2 claws to install the pad.

  14. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A003B1Z

      Attach the 3 claws to install the pad.

  15. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A003DKG

      Install the handle by pushing it in the direction of the arrow in the illustration.

    2. A003DF3E01
      Text in Illustration
      *1 Holder
      *2 Rear Door Outside Handle Frame LH

      Attach the holder of the front door outside handle frame LH.

  16. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. Attach the claw to install the cover.

    2. A003DXR

      Using a T30 "TORX" socket, tighten the screw.

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

  17. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. A003BFME01

      Install the rear door inside locking cable.

    2. A003D66

      Attach the 3 claws.

  18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. A003CF2

      Install the rear door lock remote control cable.

    2. A003DGN

      Attach the claw.

  19. INSTALL REAR DOOR WITH MOTOR 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 intrusion in the connection. 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. Install a new door lock wiring harness seal to the rear door lock assembly.

    3. A003D2FE01

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

    4. Check sure 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 }
    6. A003CGK

      Attach the clamp.

  20. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY LH


    1. w/ Power Window:


      1. A003D64E01

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

      2. A003C8ME01
        Text in Illustration
        *1 Temporary Bolt

        Temporarily install the temporary bolt onto the window regulator.

      3. Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.

        Note

        Be careful not to drop the window regulator as it may become damaged.

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

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

      5. Connect the connector.

    2. w/o Power Window:


      1. A003E4ME01

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

      2. A003C34

        Install the rear door window regulator assembly with the 3 bolts.

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

  21. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A003DUME01
      Text in Illustration
      *1 Front Side

      Install the rear door glass channel filler to the glass sub-assembly.

      Standard
      Area Specified Condition
      A 14.5 mm (0.571 in.)

  22. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH


    1. Apply soapy water to the inside of the glass channel.

    2. A003BABE01
      Text in Illustration
      *1 Front Side

      Using a plastic-faced hammer, tap the channel onto the glass to install the glass channel.

      Note

      Be careful not to damage the glass or glass channel.

      Standard
      Area Specified Condition
      A 14.5 mm (0.571 in.)

  23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. A003EMS

      Install the front side of the glass run.

    2. A003BISE01

      Apply MP grease to the sliding areas of the glass channel as shown in the illustration.

      Standard
      Area Specified Condition
      A 130 mm (5.12 in.)
      B 29 mm (1.14 in.)
    3. A003AH9

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

  24. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


    1. A003EK3E01

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

  25. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. A003EC4E01

      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.

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


    1. A003ALL

      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. A003D71E01

      Install the rear door window division bar sub-assembly with the 2 bolts and screw.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf, for bolt and screw }

  27. INSTALL REAR DOOR GLASS RUN LH


    1. A003E0FE01

      Completely install the glass run.

  28. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. Apply butyl tape to the door.

    2. A003E51E01
      Text in Illustration
      *1 Reference Point

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

      Note


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

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

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

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

    4. Connect the connector.

  29. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. A003B49

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

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


    1. A003BVM

      Install the curtain hook to the rear door frame garnish with the 2 screws.

      Tech Tips

      Use the same procedure for all curtain hooks.

  31. INSTALL REAR DOOR FRAME GARNISH LH


    1. A003C1QE01

      Attach the 2 clips to install the garnish.

  32. INSTALL REAR NO. 1 SPEAKER ASSEMBLY


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

      Note

      Do not touch the cone part of the speaker.

    2. A003AYSE01

      Using an air riveter or hand riveter, install the speaker with 3 new rivets in the order shown in the illustration.

      Note


      • A003ALIE12

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

        Text in Illustration
        *1 INCORRECT
        *2 CORRECT
        *3 Mandrel
        *4 Riveter
      • A003EMHE11

        Confirm that the rivets are seated properly against the speaker.

        Text in Illustration
        *1 INCORRECT
        *2 CORRECT
        *3 Riveter

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

      • Do not leave any space between the rivet head and speaker.

      • A003CRNE11

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

        Text in Illustration
        *1 INCORRECT
        *2 CORRECT
        *3 Riveter

    3. Connect the connector.

  33. INSTALL REAR DOOR SPEAKER GRILLE SUB-ASSEMBLY (for 11 Speakers)


    1. A003CLL

      Attach the 3 claws to install the rear door speaker grille sub-assembly.

  34. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 11 Speakers)


    1. A003CCIE01

      Align the speaker with 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.

  35. INSTALL REAR CURTAIN SUB-ASSEMBLY LH (w/ Rear Door Sunshade)


    1. Install the clip to the rear curtain sub-assembly.

    2. A003AQ7

      Attach the 2 claws to install the rear curtain sub-assembly to the door trim board.

    3. Install the 6 screws.

  36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. A003DTJ

      Connect the 2 cables to the inside handle.

    2. for 11 Speakers:

      Connect the connector.

    3. A003AO6E01
      Text in Illustration
      *1 w/ Rear Door Sunshade
      *2 w/o Rear Door Sunshade

      Attach the rear door trim board with the 4 claws on the rear door inner glass weatherstrip.

    4. A003BXN

      Install the rear door trim board with the 8 clips.

    5. Install the 3 screws.

  37. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL (w/ Power Window)


    1. Connect the connector.

    2. A003DJJ

      Attach the 6 claws and clip to install the rear power window regulator switch assembly with rear door armrest base panel.

  38. INSTALL DOOR ASSIST GRIP COVER LH


    1. A003BNU

      Attach the 10 claws to install the door assist grip cover.

  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH


    1. A003DEJ

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

  40. INSTALL REAR DOOR NO. 1 STIFFENER CUSHION


    1. A003E60

      Install the rear door No. 1 stiffener cushion.

  41. INSTALL REAR DOOR REGULATOR INSIDE HANDLE PLATE (w/o Power Window)


    1. Install the rear door regulator inside handle plate.

  42. INSTALL REAR DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)


    1. Temporarily install the rear door window regulator handle assembly and fully open the window.

    2. Install the snap ring to the rear door window regulator handle assembly.

    3. A003AQLE02

      Install the rear door window regulator handle assembly as shown in the illustration.

      Standard
      Area Specified Condition
      A 2.4° to 22.4°
      Text in Illustration
      *1 Front Side

  43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  44. INSTALL ENGINE ROOM SIDE COVER


    1. A003B3G

      Attach the 4 clips install the engine room side cover.