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 power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary 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 turns stiff and comes off easily. When the temperature is high, the tape looses elasticity.

    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 level.

        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 3 to 7 cm (1.18 to 2.76 in.) per second.

        A0041M8E02
        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 3 to 7 cm (1.2 to 2.8 in.)
        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. A00444CE09
        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 NO. 2 BLACK OUT TAPE


    1. A0040DWE02
      Text in Illustration
      *A LH Side
      *B RH Side
      *a Remove
      *b Perforation

      Remove the portion of the No. 2 black out tape at the perforation as shown in the illustration.

    2. Refer to the illustration to position the No. 2 black out tape.

      A00415KE01
      Standard Measurement
      Dimension Measurement
      A 2 to 4 mm (0.0787 to 0.157 in.)
      B 4 to 6 mm (0.157 to 0.236 in.)

    3. Remove the release paper and apply the tape.

  4. INSTALL REAR DOOR LOWER OUTSIDE STRIPE


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

      A0043IYE01
      Standard Measurement
      Dimension Measurement
      A 2.0 mm (0.0787 in.)

    2. Remove the release paper and apply the stripe.

  5. INSTALL REAR DOOR UPPER OUTSIDE STRIPE


    1. Refer to the illustration to position the rear door upper outside stripe.

      A0043HCE01
      Standard Measurement
      Dimension Measurement
      A 2.0 mm (0.0787 in.)

    2. Remove the release paper and apply the stripe.

  6. INSTALL REAR DOOR OUTSIDE STRIPE


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

      A0041M7E01
      Standard Measurement
      Dimension Measurement
      A 2.0 mm (0.0787 in.)

    2. Remove the release paper and apply the stripe.

  7. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Tech Tips

    When installing the 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. Clean the rear door front window frame moulding (if reusing the rear door front window frame moulding).


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

      2. Remove the double-sided tape from the rear door front window frame moulding.

      3. Wipe off any tape adhesive residue with cleaner.

      4. A0043DAE01
        Text in Illustration
        *1 Double-sided Tape (A)
        *2 Double-sided Tape (B)
        *3 Double-sided Tape (C)

        Apply new double-sided tape to the rear door front window frame moulding.

        Item Dimension
        A 0.8 mm (0.0315 in.)
        B 1.2 mm (0.0472 in.)
        C 5.0 mm (0.197 in.)
        D 13.0 mm (0.512 in.)
        E 35.0 mm (1.37 in.)
        F 365.0 mm (1.20 ft.)
        G 410.0 mm (1.35 ft.)
    3. A0040G1E01
      Text in Illustration
      *1 Double-sided Tape

      Install the 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 face of 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.

  8. INSTALL REAR DOOR BELT MOULDING ASSEMBLY


    1. A0040CV

      Engage the 7 claws to install the rear door belt moulding assembly.

  9. INSTALL REAR DOOR PANEL CUSHION


    1. A0044B8

      Engage the 2 claws and install 2 new rear door panel cushions.

  10. 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. A0042PB

      Engage 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 }

  11. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A0040FI

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

  12. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A00446G

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

  13. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A0041Z8

      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. A00445W

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

  14. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A0040PG

      Engage the claw and 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 }

  15. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)


    1. A004182

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

    2. A0043U6

      Engage the 4 claws as shown in the illustration.

  16. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)


    1. A003ZXL

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

    2. A004366

      Engage the 4 claws as shown in the illustration.

  17. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)


    1. A004020

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

    2. A00408W

      Engage the 2 claws as shown in the illustration.

  18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)


    1. A0042KF

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

    2. A004072

      Engage the 2 claws as shown in the illustration.

  19. INSTALL REAR DOOR LOCK ASSEMBLY (w/o Double Locking System)

    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. A0040N3

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

    3. A00414KE01

      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.

      Text in Illustration
      *1 Release Plate

    5. Using a T30 "TORX" socket 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 DOOR LOCK ASSEMBLY (w/ Double Locking System)

    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. A003ZYQ

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

    3. A0043SRE01

      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.

      Text in Illustration
      *1 Release Plate

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 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. A0041RZ

      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

      A new rear power window regulator motor assembly 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. A0042PRE01
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install rear door window regulator assembly.

    4. Tighten the temporary bolt and 5 bolts.

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

  23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the power window regulator switch assembly and move the rear door glass sub-assembly so that the door glass bolts can be seen.

    3. Disconnect the cable from the negative (-) auxiliary battery terminal.

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

    5. A0040ID

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

    6. Install the rear door glass sub-assembly with the 2 bolts.

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

  24. INSTALL REAR DOOR REAR GUIDE SEAL


    1. Install the temporary screw to the rear door rear guide seal.

    2. A004411E01
      Text in Illustration
      *1 Temporary Screw

      Temporarily install the rear door rear guide seal.

    3. Install the 2 screws.

    4. Tighten the temporary screw to install the rear door rear guide seal.

  25. INSTALL REAR DOOR WINDOW GUIDE SUB-ASSEMBLY


    1. A0043SQ

      Install the screw.

    2. Install the rear door window guide sub-assembly with the bolt.

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

  26. INSTALL REAR DOOR GLASS RUN


    1. A0043F9

      Install the rear door glass run.

  27. INSTALL REAR DOOR WEATHERSTRIP


    1. A00411Z

      Engage the 18 clips and install the rear door weatherstrip.

  28. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Apply adhesive to the threads of the bolt (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A00430PE01

      Install the rear door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      Bolt (B)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  29. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

    2. A0042JQE01
      Text in Illustration
      *1 Reference Point

      Pass the rear door lock remote control cable, rear door inside locking cable 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. Connect the 2 connectors.

    5. Engage the clamp.

  30. INSTALL REAR DOOR TRIM BRACKET


    1. A0040UH

      Install the rear door trim bracket with the 2 screws.

  31. INSTALL REAR SPEAKER ASSEMBLY


    1. Using an air riveter or a hand riveter, install the rear speaker assembly with 3 new rivets.

      A004291E01
      Text in Illustration
      *1 Riveter *2 Mandrel
      *a INCORRECT *b CORRECT

      Note


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

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

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

      Tech Tips

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

    2. Connect the connector.

  32. INSTALL REAR DOOR FRAME GARNISH


    1. A0042K3

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

  33. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 8 Speakers)


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

  34. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A0041QQ

      Engage the 7 claws and install the rear door inner glass weatherstrip to the rear door trim board sub-assembly as shown in the illustration.

  35. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A0043KG

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

    2. A00437P

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

      Note

      Make sure the 2 claws are fully engaged to ensure that the rear door lock assembly will operate properly.

  36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. for 8 Speakers:


      1. Connect the connector.

    2. A0043VB

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

    3. Install the 2 screws.

    4. Remove the protective tape.

  37. INSTALL REAR DOOR ARMREST COVER


    1. A0041EU

      Install the rear door armrest cover.

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


    1. Connect the connector.

    2. A0041MN

      Engage the 7 claws and 2 guides, and install the rear power window regulator switch assembly with rear door armrest base panel.

  39. INSTALL DOOR ASSIST GRIP COVER


    1. A0040E5

      Engage the 6 claws, 2 clips and 3 guides, and install the door assist grip cover.

  40. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A0041DE

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

  41. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  42. INSTALL REAR NO. 3 FLOOR BOARD UPPER PLATE


    1. Engage the 2 claws to install the rear No. 3 floor board upper plate.

  43. INSTALL DECK FLOOR BOX RH


    1. Install the deck floor box RH Click here.

    2. Install the rear No. 2 floor board.

  44. INSTALL REAR NO. 3 FLOOR BOARD


    1. Install the rear No. 3 floor board.

  45. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  46. INSPECT POWER WINDOW OPERATION

    Click here