REAR DOOR INSTALLATION

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. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


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

      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 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 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 falls off easily. When the temperature is high, the tape loses elasticity.

    3. Before installation.


      1. Make sure any dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame) is removed, and that the surface is smooth. If the surface is rough 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 the installation of the tape (how to use a squeegee and the installation procedure for flat surfaces).

      Note


      • Position the tape with a high level of accuracy to achieve a neat finish and to avoid peeling.

      • The tape cannot be reused because it deforms and will not fit after removal.


      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 40 to 50° (for pressing forward) or 30 to 45° (for pulling) from the vehicle body surface and press with a force of 20 to 30 N (2 to 3 kgf) while moving the squeegee at a constant slow speed of 3 to 7 cm (1.2 to 2.8 in.) per second.

        A01IQJ8E13

        Note

        Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles and air bubbles.

        Tech Tips


        • Either angle of the squeegee (for pressing forward or for pulling) is acceptable.

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.393 to 0.787 in.) from the edge of the squeegee.

    6. A01ITRPE05

      Key points for the installation of the tape (how to use a squeegee and the installation procedure for hemming surfaces).


      1. If it is difficult to press the tape, press 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 the installation of the tape (how to use a squeegee and the 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 to avoid wrinkles on the tape and 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, apply new tape.

        Note

        Do not reuse the tape.

  2. INSTALL NO. 4 BLACK OUT TAPE LH

    A01IQHNE01

    1. Refer to the illustration to position a new No. 4 black out tape.

      Standard
      Area Dimension
      A 5 mm (0.197 in.)
      B 2 to 4 mm (0.078 to 0.158 in.)
    2. Remove the release paper and apply the tape.

  3. INSTALL NO. 3 BLACK OUT TAPE LH

    A01IP98E01

    1. Refer to the illustration to position a new No. 3 black out tape.

      Standard
      Area Dimension
      A 2 to 4 mm (0.078 to 0.158 in.)
      B 5 mm (0.197 in.)
      C 5 mm (0.197 in.)
      D 2 to 4 mm (0.078 to 0.158 in.)
    2. Remove the release paper and apply the tape.

  4. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH

    A01IPDH

    1. Attach the 8 claws to install the rear door belt moulding.

  5. INSTALL REAR DOOR WEATHERSTRIP LH


    1. A01IOIX

      Attach the 18 clips to install the weatherstrip.

  6. INSTALL REAR DOOR CHECK ASSEMBLY LH


    1. A01ISY0

      Apply MP grease to the sliding areas of the door check.

    2. Install the door check to the door panel with the 2 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    3. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    4. Install the door check to the body panel with the bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
  7. INSTALL NO. 3 SEPARATION DOOR STIFFENER CUSHION


    1. A01IS0J

      Attach the 2 claws to install the No. 3 separation door stiffener cushion to the body panel, and then install the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
  8. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH


    1. A01IOMW

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

    2. Attach the claw to install the rear door outside handle frame sub-assembly.

    3. Using a T30 "TORX" socket, tighten the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
  9. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A01IUD6

      Attach the 2 claws to install the pad.

  10. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A01IOG7

      Attach the 3 claws to install the pad.

  11. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A01IPH6

      Install the handle by pushing it in the direction of the arrow in the illustration.

    2. A01ISAZE01
      Text in Illustration
      *1 Holder
      *2 Rear Door Outside Handle Frame LH

      Attach the holder of the rear door outside handle frame LH.

  12. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


    1. Attach the claw to install the cover.

    2. A01IU6D

      Using a T30 "TORX" socket, tighten the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
  13. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. A01IU92E01

      Install the rear door inside locking cable.

    2. A01ISH1E01

      Attach the 3 claws.

  14. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. A01IS8IE01

      Install the rear door lock remote control cable.

    2. A01IUHXE01

      Attach the claw.

  15. 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 adhere to the surface of the connector which contacts the door lock wiring harness seal.

    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may allow water into the connection. 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. A01ISYXE01

      Insert the rear door lock assembly into the rear door outside handle release plate, and set it on the rear door panel.

    4. Check that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
  16. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY LH


    1. w/ Power Window:


      1. A01ITGPE01

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

      2. A01IQMLE01
        Text in Illustration
        *1 Temporary Bolt

        Temporarily install the temporary bolt to the window regulator.

      3. Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.

        Note

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

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

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

    2. w/o Power Window:


      1. A01IO8SE01

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

      2. A01ISQG

        Install the rear door window regulator assembly with the 3 bolts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
  17. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A01IQCBE01
      Text in Illustration
      *1 Front Side

      Install the rear door glass channel filler to the glass sub-assembly.

      Standard
      Area Specified Condition
      A 10.0 mm (0.394 in.)
    2. Apply soapy water to the inside of the glass channel.

    3. A01INCTE01
      Text in Illustration
      *1 Front Side

      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.

      Standard
      Area Specified Condition
      A 10.0 mm (0.394 in.)
  18. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. w/ Power Window:


      1. Temporarily install the regulator switch assembly.

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

      3. Operate the regulator switch until the regulator reaches its bottom dead center.

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

        Note

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

      5. Remove the regulator switch assembly.

    2. w/o Power Window:


      1. Temporarily install the rear door window regulator handle assembly.

      2. Turn the handle until the regulator reaches its bottom dead center.

      3. Remove the rear door window regulator handle assembly.

    3. A01IQGG

      Install the front side of the glass run.

    4. A01IS5SE02

      Apply MP grease to the sliding areas of the glass channel as shown in the illustration.

      Standard
      Area Specified Condition
      A 130 mm (5.12 in.)
      B 29 mm (1.14 in.)
    5. A01IOSY

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

  19. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


    1. A01IQ3A

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

  20. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. A01ITDR

      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.

  21. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH


    1. A01IT1R

      Insert the rear door window division bar sub-assembly from above.

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

    3. A01ISN0

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

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf, for bolt and screw }
  22. INSTALL CURTAIN HOOK (w/ Rear Door Sunshade)


    1. A01IP9N

      Install the 2 curtain hooks.

  23. INSTALL REAR DOOR FRAME GARNISH LH


    1. A01INU9

      Attach the clip to install a new door frame garnish.

  24. INSTALL REAR DOOR GLASS RUN LH


    1. A01IS5C

      Completely install the glass run.

  25. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. Apply butyl tape to the door.

    2. A01IQJEE01
      Text in Illustration
      *1 Reference Point

      Pass the rear door lock remote control cable and rear door inside locking cable through a new rear door service hole cover.

    3. Install the rear door service hole cover by using the reference points on the rear door panel.

      Note


      • There should be no wrinkles or folds after attaching the service hole cover.

      • After attaching the service hole cover, check the seal quality.

    4. Connect the connector.

  26. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY LH

    Note

    When reusing the removed rear door inside panel reinforce sub-assembly, replace the rear lower door hole cover with a new one.


    1. A01IMXU

      Install the rear door inside panel reinforce sub-assembly to the door panel with the 2 bolts and 2 screws.

  27. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. A01ITY6

      Install the rear door inner glass weatherstrip to the door panel.

  28. INSTALL REAR NO. 1 SPEAKER ASSEMBLY

    Note

    Do not touch the cone part of the speaker.


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

    2. A01IS1W

      Using an air riveter or hand riveter, install the speaker with 3 new rivets.

      Note


      • A01ISHTE12

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

        Text in Illustration
        *1 INCORRECT
        *2 CORRECT
        *3 Mandrel
        *4 Riveter
      • A01IUM1E11

        Confirm that the rivets are seated properly against the speaker.

        Text in Illustration
        *1 INCORRECT
        *2 CORRECT
        *3 Riveter
      • Do not tilt the riveter when installing the rivet to the speaker.

      • Do not leave any space between the rivet head and speaker.

      • A01IQGIE11

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

        Text in Illustration
        *1 INCORRECT
        *2 CORRECT
        *3 Riveter
    3. Connect the connector.

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


    1. A01IRRB

      Install the rear curtain sub-assembly to the door trim board with the 10 screws.

  30. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. A01ISMJ

      Connect the 2 cables to the inside handle to install the inside handle.

  31. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. A01IODC

      Install the clamp to the door panel.

    2. A01IO4S

      Attach the 2 claws to install the inside handle to the rear door trim board.

    3. A01IQESE01
      Text in Illustration
      *1 w/ Rear Door Sunshade
      *2 w/o Rear Door Sunshade

      Attach the rear door trim board with the 4 claws on the rear door inner glass weatherstrip.

    4. A01IP0B

      Install the rear door trim board with the 10 clips.

    5. Install the 3 screws.

  32. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL (w/ Power Window)


    1. Connect the connector.

    2. A01IREP

      Attach the 4 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

  33. INSTALL REAR DOOR TRIM MOULDING LH


    1. A01IR9Q

      Attach the 8 claws to install the door trim moulding.

  34. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH


    1. A01IT23

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

  35. INSTALL REAR DOOR REGULATOR INSIDE HANDLE PLATE (w/o Power Window)


    1. Install the rear door regulator inside handle plate.

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


    1. Temporarily install the rear door window regulator handle assembly, fully close the window, and then remove the rear door window regulator handle assembly.

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

    3. A01IR9XE01
      Text in Illustration
      *1 Front Side

      Install the rear door window regulator handle assembly as shown in the illustration.

      Standard
      Area Specified Condition
      A 50° to 60°
  37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  38. INSTALL BATTERY SERVICE HOLE COVER


    1. A01ITOM

      Install the battery service hole cover with the clip.