REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RHD and LHD vehicle.

  • The procedure listed below is for the LHD vehicle.

PROCEDURE


  1. INSTALL NO.3 BLACK OUT TAPE

    Click here

  2. INSTALL NO.4 BLACK OUT TAPE

    Click here

  3. INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP


    1. A005HXKE01

      Engage the 17 clips.

    2. Engage the clip A and install the rear door opening trim weatherstrip.

  4. INSTALL REAR DOOR FRAME GARNISH


    1. A005LWN

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

  5. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. A005GO6

      Attach the rear door outside handle frame sub-assembly in the direction indicated by the arrow as shown in the illustration.

    3. Engage the 2 claws.

    4. A005K96E01
      Text in Illustration
      *1 Grommet

      Engage the grommet.

    5. Using a "TORX" socket wrench T30, install the rear door outside handle frame sub-assembly with the screw.

  6. INSTALL REAR DOOR OUTSIDE HANDLE REAR PAD


    1. A005IYH

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

  7. INSTALL REAR DOOR OUTSIDE HANDLE FRONT PAD


    1. A005IO8

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

  8. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A005HIP

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

    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly, then slide the rear door outside handle assembly toward the front of the vehicle and install it.

  9. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A005LLY

      Using a "TORX" socket wrench T30, install the rear door outside handle cover.

  10. INSTALL REAR DOOR LOCK ASSEMBLY

    Click here

  11. INSTALL REAR DOOR CHECK ASSEMBLY

    A005KKDE03

    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. Install the rear door check assembly with the 3 bolts.

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

  12. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  13. INSTALL REAR DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Click here

  14. INSTALL REAR DOOR GLASS RUN


    1. A005KJY

      Install the rear door glass run.

  15. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/ Power Window)


    1. Apply MP grease to the sliding parts of the rear door window regulator assembly.

    2. A005LTHE01
      Text in Illustration
      *1 Temporarily Bolt

      Install the temporary bolt.

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

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

    4. Connect the connector.

  16. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/o Power Window)


    1. A005HMQ

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

    2. Install the rear door window regulator sub-assembly with the 3 bolts.

  17. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A005IS0E01

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

      Standard
      A 10 mm (0.393 in.)
      B 10 mm (0.393 in.)
      Text in Illustration
      A005GO2 Front Side
      A005IBX Rear Side
    2. A005IO1E01

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

      Standard
      A 10 mm (0.393 in.)
      B 10 mm (0.393 in.)
      Text in Illustration
      A005GO2 Front Side
      A005IBX Rear Side

    3. 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.

  18. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A005KWX

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

      Note

      Do not damage the rear door glass.

  19. INSTALL REAR DOOR REAR GUIDE SEAL


    1. A005HKJ

      Install the rear door rear guide seal with 2 screws.

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

    2. Install the bolt.

  20. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY


    1. A005GWY

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

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

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

  21. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

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

    3. A005HKKE02
      Text in illustration
      *1 Reference Point

      Install 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.

    4. Connect the connector.

  22. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  23. INSTALL REAR DOOR GLASS INNER WEATHERSTRIP


    1. A005M9L

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

  24. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A005JYZ

      Install the 4 guides and the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

  25. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A005KSGE02
      Text in illustration
      *1 Rear Door Lock Remote Control Cable Assembly
      *2 Rear Door Inside Locking Cable Assembly

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

    2. Attach the upper section of the rear door trim board sub-assembly to the door panel.

    3. A005J5Q

      Engage the 7 clips.

    4. A005IHJ

      Install the 2 screws and install the rear door trim board sub-assembly.

    5. A005M6YE02
      Text in illustration
      *1 Cover

      Install the screw and close the cover.

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

    A005J0IE01
    Text in illustration
    *1 Rear Door Regulator Inside Handle Plate
    *2 Rear Door Window Regulator Handle Shaft Snap Ring
    *a Upper Side
    A005IBX Front Side

    1. Install the rear door regulator inside handle plate.

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

  27. INSTALL REAR DOOR UPPER ARMREST BASE PANEL (w/ Power Window)


    1. Connect the connector (w/ Power Window).

    2. A005JMC

      Engage the 2 clips and 8 claws, and install the rear door upper armrest base panel to the rear door trim board sub-assembly.

  28. INSTALL REAR DOOR UPPER ARMREST BASE PANEL (w/o Power Window)

    Tech Tips

    Use the same procedure for the rear door upper armrest base panel (w/ Power Window).

  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    Note

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

  30. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here