REAR DOOR REASSEMBLY

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 WINDOW FRAME MOULDING SUB-ASSEMBLY LH


    1. Attach the 2 claws to install the rear door window frame moulding.

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

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

    4. Place the riveter upright against the rear door window frame moulding and install the 8 rivets.

      Tech Tips

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

      Note


      • A01FU18E15

        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
        *b CORRECT
      • A01FS5BE17

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

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

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

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT
      • A01FSKYE15

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

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT
      A01FTCM

  2. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH

    Tech Tips

    When installing the rear door front window frame moulding, heat the rear door panel and rear door front window frame moulding using a heat light.

    Standard
    Item Temperature
    Rear Door Panel 40 to 60°C (104 to 140°F)
    Rear Door Front Window Frame Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the rear door panel or rear door front window frame moulding excessively.


    1. Clean the rear door panel surface.


      1. Using a heat light, heat the rear door panel surface.

      2. Remove the double-sided tape from the rear door panel surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. A01FR0FE01
      Text in Illustration
      *1 Double-sided Tape
      *2 Butyl Tape

      Install a new rear door front window frame moulding.


      1. Using a heat light, heat a new rear door front window frame moulding and the rear door panel surface.

      2. Remove the peeling paper from the face of the rear door front window frame moulding.

        Tech Tips

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

      3. Attach the clip and guide to install the rear door front window frame moulding.

        Tech Tips

        Press the rear door front window frame moulding firmly to install it.

  3. INSTALL REAR DOOR FRONT BELT MOULDING END COVER LH

    Tech Tips

    When installing the rear door front belt moulding end cover, heat the rear door panel and rear door front belt moulding end cover using a heat light.

    Standard
    Item Temperature
    Rear Door Panel 40 to 60°C (104 to 140°F)
    Rear Door Front Belt Moulding End Cover 20 to 30°C (68 to 86°F)

    Note

    Do not heat the rear door panel or rear door front belt moulding end cover excessively.


    1. Clean the rear door panel surface.


      1. Using a heat light, heat the rear door panel surface.

      2. Remove the double-sided tape from the rear door panel surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. A01FSR7E01
      Text in Illustration
      *1 Double-sided Tape

      Install a new rear door front belt moulding end cover.


      1. Using a heat light, heat a new rear door front belt moulding end cover and the rear door panel surface.

      2. Remove the peeling paper from the face of the rear door front belt moulding end cover.

        Tech Tips

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

      3. Attach the 2 clips to install the rear door front belt moulding end cover.

        Tech Tips

        Press the rear door front belt moulding end cover firmly to install it.

  4. INSTALL REAR DOOR WEATHERSTRIP LH


    1. Attach the 22 clips to install the rear door weatherstrip.

  5. INSTALL REAR DOOR CHECK ASSEMBLY LH


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

    2. When reusing a bolt:


      1. Clean the threads of the bolt with non-residue solvent.

      2. Apply adhesive to the threads of the bolt.

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

    3. Install the rear door check with the 2 nuts and bolt.

      Torque:
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  6. INSTALL REAR DOOR PANEL CUSHION


    1. Install a new rear door panel cushion.

  7. INSTALL REAR DOOR DUST PROOF SEAL


    1. Attach the claw to install a new rear door proof seal.

  8. INSTALL REAR DOOR NO. 3 WEATHERSTRIP LH

    Tech Tips

    When installing the rear door No. 3 weatherstrip, heat the rear door panel using a heat light.

    Standard
    Item Temperature
    Rear Door Panel 40 to 60°C (104 to 140°F)

    Note

    Do not heat the rear door panel excessively.


    1. Clean the rear door panel surface.


      1. Using a heat light, heat the rear door panel surface.

      2. Remove the double-sided tape from the rear door panel surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new rear door No. 3 weatherstrip.


      1. Using a heat light, heat the rear door panel surface.

      2. Remove the peeling paper from the face of the rear door No. 3 weatherstrip.

        Tech Tips

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

      3. Install the rear door No. 3 weatherstrip.

        Tech Tips

        Press the rear door No. 3 weatherstrip firmly to install it.

  9. INSTALL REAR DOOR NO. 2 WEATHERSTRIP LH


    1. Attach the 5 clips to install the rear door No. 2 weatherstrip.

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


    1. Apply MP grease to the sliding area of the rear door outside handle frame.

    2. Attach the clamp of the rear door wire to the rear door outside handle frame.

    3. Using a T30 "TORX" socket wrench, install the rear door outside handle frame with the screw.

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

  11. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD LH


    1. Attach the 2 claws to install the rear door rear outside handle pad.

  12. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


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

  13. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. Apply MP grease to the sliding area of the rear door outside handle.

    2. A01FUZV

      Install the rear door outside handle by moving it in the direction indicated by the arrow shown in the illustration.

    3. A01FUE5E01
      Text in Illustration
      *1 Holder

      Attach the holder in the direction indicated by the arrow in the illustration.

    4. Attach the claw of the connector to connect the connector.

    5. Attach the 2 claws of the connector cover to connect the connector cover.

  14. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. 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 LH


    1. Install the rear door inside locking cable.

    2. Attach the 3 claws to close the cover.

  16. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the rear door lock remote control cable.

    2. Attach the claw to close the cover.

  17. INSTALL REAR DOOR 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 contact 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. Install a new door lock wiring harness seal to the rear door lock assembly.

    3. A01FSS3E01
      Text in Illustration
      *A w/o Double Locking System
      *B w/ Double Locking System

      Insert the rear door lock assembly to the rear door outside handle frame 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:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    6. Connect the connector.

  18. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


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

    2. Temporarily install the temporary bolt to the rear door window regulator.

    3. A01FS3ZE01
      Text in Illustration
      *1 Temporary Bolt

      Install the rear door window regulator with the 3 bolts, and then tighten the temporary bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

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

    4. Connect the connector.

  19. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH


    1. attach the 4 claws to install the rear door belt moulding.

  20. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A01FUSSE01
      Text in Illustration
      *a Front Side

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

      Standard
      Area Dimension
      A 12.0 mm (0.472 in.)

  21. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH


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

    2. A01FR3OE01
      Text in Illustration
      *a Front Side

      Using a plastic-faced hammer, tap the rear door glass channel onto the rear door glass to install the rear door glass channel as shown in the illustration.

      Standard
      Area Dimension
      A 21.0 mm (0.827 in.)

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. Temporarily install the rear power window regulator switch assembly with rear door armrest base panel.

    2. Connect the cable to the negative (-) auxiliary battery terminal.

    3. Operate the rear door window regulator so that the rear door glass can be installed.

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

      Note

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

    5. Remove the rear power window regulator switch assembly with rear door armrest base panel.

    6. Install the front side of the rear door glass run.

    7. A01FUGSE01
      Text in Illustration
      *1 MP Grease

      Apply MP grease to the sliding area of the rear door glass channel as shown in the illustration.

      Standard
      Area Specified Condition
      A 122 mm (4.80 in.)
      B 35 mm (1.38 in.)
    8. A01FTCO

      Install the rear door glass channel to the rear door window regulator as shown in the illustration.

      Note

      Do not damage the door glass.

  23. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


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

  24. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. Install the rear door quarter window glass.

  25. INSTALL REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY LH


    1. Align the rear door glass run with the rear door rear lower window frame.

    2. Insert the rear door rear lower window frame together with the rear door glass run into the rear door panel.

    3. Partially install the screw and 2 bolts.

    4. Install the upper side of the rear door glass run.

  26. INSTALL REAR DOOR GLASS RUN LH


    1. Finish installing the rear door glass run.

  27. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. Apply new butyl tape to the rear door panel.

    2. A01FT41E01
      Text in Illustration
      *a Reference Point

      Pass the rear door inside locking cable and rear door lock remote control cable through a new rear door service hole cover, and then attach the rear door service hole cover using the reference points on the rear door panel.

      Note


      • Securely install the rear door service hole cover to prevent wrinkles and air bubbles.

      • There should be no wrinkles or folds after installing the rear door service hole cover.

      • After installing the rear door service hole cover, check the seal quality.

  28. INSTALL REAR SPEAKER ASSEMBLY


    1. A01FQFAE02
      Text in Illustration
      *A w/o Mark Levinson Speaker System
      *B w/ Mark Levinson Speaker System

      Connect the speaker connector.

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

    3. Install the rear speaker assembly with the 3 screws.

      Note

      Do not touch the cone of the speaker.

      Tech Tips

      Tighten the screws in the order shown in the illustration.

  29. INSTALL REAR NO. 2 SPEAKER ASSEMBLY


    1. Attach the clip to install the rear No. 2 speaker assembly.

      Note

      Do not touch the cone of the speaker.

    2. Connect the connector.

  30. INSTALL REAR DOOR ARMREST SET BRACKET LH


    1. Install the rear door armrest set bracket with the 2 screws.

  31. INSTALL REAR DOOR FRAME GARNISH LH


    1. Attach the 2 clips to install the rear door frame garnish.

  32. INSTALL REAR SIDE CURTAIN ASSEMBLY LH (w/ Rear Sunshade)


    1. Attach the 2 clips and 4 claws to install the rear side curtain.

  33. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. Install the rear door inner glass weatherstrip.

  34. INSTALL REAR DOOR TRIM COVER LH


    1. Attach the 6 clips to install the rear door trim cover.

  35. INSTALL REAR DOOR NO. 1 STIFFENER CUSHION


    1. Install the rear door No. 1 stiffener cushion.

  36. INSTALL REAR DOOR TRIM SEAL LH


    1. Attach the 9 clips to install the rear door trim seal.

  37. INSTALL NO. 2 COURTESY LIGHT ASSEMBLY


    1. Connect the connector.

    2. Attach the claw to install the No. 2 courtesy light assembly.

  38. INSTALL REAR DOOR TRIM ORNAMENT SUB-ASSEMBLY LH


    1. Attach the 3 claws to install the rear door trim ornament to the No. 1 interior illumination light.

  39. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the claw to install the rear door inside handle.

    2. Install the screw.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Install the rear door inside handle together with the rear door trim ornament and No. 1 interior illumination light with the 14 screws.

  40. INSTALL REAR DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH


    1. Connect the connector.

    2. Attach the claw and install the rear door inside handle illumination light assembly LH

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


    1. Install the rear curtain with the 7 screws.

  42. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


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

    2. Connect each connector.

    3. A01FSKEE01
      Text in Illustration
      *1 Reference Boss

      Attach the 3 claws to install the rear door trim board to the rear door inner glass weatherstrip.

    4. Attach the reference boss in the direction indicated by the arrow in the illustration.

    5. Attach the 8 clips to install the rear door trim board.

    6. Install the 3 screws.

  43. INSTALL REAR DOOR HOLE COVER


    1. Install the rear door hole cover.

  44. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH


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

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


    1. Connect the connector.

    2. Attach the 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

  46. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  47. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH


    1. Install the luggage compartment trim cover LH.

  48. INSTALL LUGGAGE COMPARTMENT FLOOR MAT


    1. Install the luggage compartment floor mat.

  49. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  50. CHECK POWER WINDOW CONTROL SYSTEM

    Click here

  51. CHECK POWER DOOR LOCK CONTROL SYSTEM

    Click here