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

        A003X7RE02
        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 (1.18 to 2.76 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. A003XUCE09
        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.

  2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE


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

      A003YS9E01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Straight
      *c Cutout - -
      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.

      A003WT9E01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Straight
      *c Cutout - -
      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 WINDOW FRAME MOULDING SUB-ASSEMBLY


    1. A003YVT

      Engage the guide and 2 claws, and install the rear door window frame moulding sub-assembly to the door frame.

    2. Using an air riveter or hand riveter with a nose piece, install the rear door upper window frame moulding with 7 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


      • A003YE3E09

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

        Text in Illustration
        *1 Riveter
        *2 Mandrel
        *a Incorrect
      • A003ZTQE10

        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.

        Text in Illustration
        *1 Riveter
        *a Incorrect
      • A003XD6E12

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

        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. A003XBPE01
      Text in Illustration
      *1 Double-sided Tape
      *2 Caulking Sponge

      Install a new 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 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 NO. 3 REAR DOOR WEATHERSTRIP

    Tech Tips

    When installing a new No. 3 rear door weatherstrip, heat the vehicle body and No. 3 rear door weatherstrip using a heat light.

    Note

    Do not heat the vehicle body or No. 3 rear door weatherstrip excessively.


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

      Heating Temperature
      Item Temperature
      Vehicle Body 40 to 60°C (104 to 140°F)
      No. 3 Rear Door Weatherstrip 20 to 30°C (68 to 86°F)

    2. Remove the double-sided tape from the vehicle body.

    3. Wipe off any tape adhesive residue with cleaner.

    4. A003VDDE01
      Text in Illustration
      *1 Double-sided Tape

      Install a new No. 3 rear door weatherstrip.

  7. INSTALL REAR DOOR BELT MOULDING ASSEMBLY


    1. A003W25

      Engage the 5 claws and guide to install the rear door belt moulding assembly as shown in the illustration.

  8. INSTALL REAR DOOR PANEL CUSHION


    1. A003WPO

      Engage the claw and install a new rear door panel cushion.

  9. INSTALL NO. 2 REAR DOOR WEATHERSTRIP


    1. A003X0S

      Engage the 4 clips to install the No. 2 rear door weatherstrip.

  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. A003XYQ

      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. A003ZRJ

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

  12. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A003VIS

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

  13. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A003WI5

      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. A003V27

      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. A003YSN

      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. A003V8R

      Install the rear door inside locking cable assembly.

    2. A003W6W

      Engage the 3 claws.

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


    1. A003Y6E

      Install the rear door inside locking cable assembly.

    2. A003WRB

      Engage the 3 claws.

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


    1. A003ZTX

      Install the rear door lock remote control cable assembly.

    2. A003Y7Z

      Engage the claw.

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


    1. A003ZW7

      Install the rear door lock remote control cable assembly.

    2. A003XJ3

      Engage the claw.

  19. INSTALL REAR DOOR LOCK ASSEMBLY

    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. A003V8C

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

    3. A003YTS

      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. A003XI4

      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

      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.

  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. A003W3UE05
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the rear door window regulator assembly.

    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 }

  22. INSTALL REAR DOOR CUSHION


    1. When reusing the rear door cushion:


      1. Clean the rear door cushion.

      2. Remove the double-sided tape from the rear door cushion.

      3. Wipe off any tape adhesive residue with cleaner.

      4. A003XGPE01

        Apply new double-sided tape to the rear door cushion as shown in the illustration.

        Area Dimension
        (A) 80.0 mm (3.150 in.)
        (B) 20.0 mm (0.787 in.)
        (C) 4.0 mm (0.157 in.)

    2. Clean the rear door panel sub-assembly.

    3. A003WP9E01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 2 guides.

    4. Install the rear door cushion with the 2 bolts.

  23. INSTALL REAR DOOR GLASS CHANNEL FILLER


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

    2. A003WF2E01
      Text in Illustration
      *A Front Side
      *B Rear Side
      *a 0 mm (0 in.)
      *b 0 mm (0 in.)
      *c Edge of curved surface

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

  24. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY


    1. Apply soapy water to the channel filler side of the rear door glass channel sub-assembly.

    2. A003ZAIE01
      Text in Illustration
      *A Front Side
      *B Rear Side
      *a 14.0 mm (0.551 in.)
      *b 11.0 mm (0.433 in.)
      *c Edge of curved surface

      Using a plastic hammer, install the rear door glass channel sub-assembly to the position shown in the illustration.

      Note

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

  25. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A003V47

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

  26. INSTALL NO. 2 REAR DOOR VENT SEAL


    1. A003YMR

      Install the No. 2 rear door vent seal.

  27. INSTALL REAR DOOR QUARTER WINDOW GLASS


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

    2. A003ZNX

      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.

  28. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY


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

    2. A003ZUUE01
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the rear door window division bar sub-assembly.

    3. Install the bolt and screw.

      Torque:
      Bolt
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

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

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  29. INSTALL NO. 1 REAR DOOR VENT SEAL


    1. A003ZME

      Install the No. 1 rear door vent seal.

  30. INSTALL REAR DOOR GLASS RUN


    1. A003VUE

      Install the rear door glass run.

  31. INSTALL REAR DOOR WEATHERSTRIP


    1. A003YQNE01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 23 clips to install a new rear door weatherstrip.

  32. 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 (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A003WBDE01

      Install the rear door check assembly with the 3 bolts.

      Torque:
      (A)
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      (B)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  33. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

    2. A003W4EE01
      Text in Illustration
      *1 Reference Point

      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.

    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.

    5. Engage the clamp.

  34. INSTALL REAR DOOR TRIM BRACKET


    1. A003VYL

      Install the rear door trim bracket with the 2 screws.

  35. INSTALL REAR DOOR FRAME GARNISH


    1. A003VY0

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

  36. INSTALL REAR DOOR SPEAKER COVER (w/o Rear Speaker)


    1. A003W84E01

      Install the rear door speaker cover with the 3 bolts.

      Tech Tips

      Install the bolts in the order shown in the illustration.

    2. Connect the connector.

  37. INSTALL REAR SPEAKER ASSEMBLY (w/ Rear Speaker)


    1. A003V5UE01

      Install the rear speaker assembly with the 3 bolts.

      Note

      Do not touch the speaker cone.

      Tech Tips

      Install the bolts in the order shown in the illustration.

    2. Connect the connector.

  38. INSTALL REAR DOOR TRIM SEAL


    1. A003X3A

      Engage the 6 clips of the rear door trim seal.

  39. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A003WKG

      Engage the 3 claws and install the rear door inner glass weatherstrip as shown in the illustration.

  40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A003ZU0

      Engage the claw and 2 guides, and install the rear door inside handle sub-assembly to the rear door trim board sub-assembly as shown in the illustration.

  41. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. Install a new rear door trim board clip (blue) to the rear door trim board.

    2. A003ZMDE01
      Text in Illustration
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly

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

    3. Connect the connector.

    4. A003V4Z

      Engage the rear door trim board sub-assembly with the 3 claws to the rear door inner glass weatherstrip as shown in the illustration.

    5. A003VT0E01

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

    6. Engage the clip <A> and install the rear door trim board sub-assembly.

    7. Install the 2 screws.

    8. Remove the protective tape.

  42. INSTALL REAR DOOR ARMREST COVER


    1. A003WKN

      Install the rear door armrest cover.

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


    1. Connect the connector.

    2. A003V84

      Engage the 2 guides, 3 clips and 4 claws, and install the rear power window regulator switch assembly with rear door armrest base panel.

  44. INSTALL REAR DOOR REAR FRAME BRACKET


    1. A003WT2

      Engage the 3 guides, clip and 3 claws, and install the rear door rear frame bracket.

  45. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A003XES

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

  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  47. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.

  48. INSTALL DECK FLOOR BOX RH


    1. Engage the 6 guides.

    2. Install the deck floor box RH with the clip.

  49. INSTALL REAR NO. 3 FLOOR BOARD


    1. Install the rear No. 3 floor board.

  50. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  51. INSTALL REAR NO. 2 FLOOR BOARD


    1. Install the rear No. 2 floor board.

  52. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here