REAR DOOR REASSEMBLY


  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 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.

        A01JD1KE01

        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. A01JAD5E01

        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.

  2. INSTALL NO. 2 BLACK OUT TAPE


    1. A01JB6NE01

      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.

      A01J8R6E01
      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.

  3. INSTALL REAR DOOR LOWER OUTSIDE STRIPE


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

      A01J9LBE01
      Standard Measurement
      Dimension Measurement
      A 2.0 mm (0.0787 in.)

    2. Remove the release paper and apply the strip.

  4. INSTALL REAR DOOR UPPER OUTSIDE STRIPE


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

      A01JBB3E01
      Standard Measurement
      Dimension Measurement
      A 2.0 mm (0.0787 in.)

    2. Remove the release paper and apply the strip.

  5. INSTALL REAR DOOR OUTSIDE STRIPE


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

      A01JBS1E01
      Standard Measurement
      Dimension Measurement
      A 2.0 mm (0.0787 in.)

    2. Remove the release paper and apply the strip.

  6. 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. A01JAUKE01
        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. A01J9KDE01
      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.

  7. INSTALL REAR DOOR BELT MOULDING ASSEMBLY


    1. A01J9KC

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

  8. INSTALL REAR DOOR PANEL CUSHION


    1. A01JBX9

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

  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. A01JAQQ

      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 }

  10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A01JA7C

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

  11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A01J8NH

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

  12. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A01JBMA

      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. A01JCE3

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

  13. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A01JD8D

      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 }

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


    1. A01JBN3

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

    2. A01J8SF

      Engage the 4 claws as shown in the illustration.

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


    1. A01J8NV

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

    2. A01JD0H

      Engage the 4 claws as shown in the illustration.

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


    1. A01JBLN

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

    2. A01JCFU

      Engage the 2 claws as shown in the illustration.

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


    1. A01JCRS

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

    2. A01JCXI

      Engage the 2 claws as shown in the illustration.

  18. 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. A01JDAN

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

    3. A01JAAU

      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.

    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 }

  19. 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. A01JDAX

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

    3. A01J9CN

      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.

    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 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. A01JCM6

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

  21. 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. A01JCNCE01
      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 }

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


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


      1. w/ Navigation System for HDD:

        Note

        After the power switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

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

    5. A01JC4L

      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 }

    7. Connect the cable to the negative (-) battery terminal.

      Note

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

  23. INSTALL REAR DOOR REAR GUIDE SEAL


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

    2. A01J8Q9E01
      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.

  24. INSTALL REAR DOOR WINDOW GUIDE SUB-ASSEMBLY


    1. A01JA23

      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 }

  25. INSTALL REAR DOOR GLASS RUN


    1. A01JCIU

      Install the rear door glass run.

  26. INSTALL REAR DOOR WEATHERSTRIP


    1. A01JBM1

      Engage the 18 clips and install the rear door weatherstrip.

  27. 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. A01JBS9E01

      Install the rear door check assembly with the 3 bolts.

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

  28. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

    2. A01JCSJE01
      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.

  29. INSTALL REAR DOOR TRIM BRACKET


    1. A01JAN5

      Install the rear door trim bracket with the 2 screws.

  30. INSTALL REAR SPEAKER ASSEMBLY


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

      A01JA95E01
      Text in Illustration
      *1 Riveter *2 Mandrel
      *a INCORRECT - -

      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. A01J9Z3

      Connect the connector.

  31. INSTALL REAR DOOR FRAME GARNISH


    1. A01J92B

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

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


    1. A01J9DZ

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

  33. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A01J8PW

      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.

  34. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01JA0W

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

    2. A01J8OM

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

  35. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. for 8 Speakers:


      1. Connect the connector.

    2. A01J8PS

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

    3. Install the 2 screws.

    4. Remove the protective tape.

  36. INSTALL REAR DOOR ARMREST COVER


    1. A01JBG5

      Install the rear door armrest cover.

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


    1. Connect the connector.

    2. A01JBGI

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

  38. INSTALL DOOR ASSIST GRIP COVER


    1. A01J8GK

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

  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A01J9NW

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

  40. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  41. INSTALL REAR NO. 3 FLOOR BOARD


    1. A01JC33

      Engage the 2 guides to install the rear No. 3 floor board.

  42. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  43. INSTALL REAR NO. 2 FLOOR BOARD


    1. A01JCWRE01

      Engage the 3 guides <A>.

    2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.