REAR DOOR(for Double Cab) REASSEMBLY

CAUTION / NOTICE / HINT

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.

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PROCEDURE


  1. REPAIR INSTRUCTION (w/ Black Out Tape)

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  2. INSTALL NO. 2 BLACK OUT TAPE LH (w/ Black Out Tape)

    Click here

  3. INSTALL REAR DOOR DUST PROOF SEAL


    1. B00248C

      Attach the claw to install 3 new front door dust proof seals.

  4. INSTALL REAR DOOR WEATHERSTRIP LH


    1. B0027YV

      Attach the clip to install the rear door weatherstrip LH.

  5. INSTALL REAR DOOR CHECK ASSEMBLY LH


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

    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 (B).

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. B00270SC02
      B0068HS Bolt (A)
      B006964 Bolt (B)

      Install the rear door check assembly LH with the 2 bolts (A) and bolt (B).

      Torque:
      Bolt (A)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt (B)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  6. INSTALL REAR DOOR PANEL CUSHION


    1. B0025T1

      Attach the claw to install a new rear door panel cushion.

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


    1. Apply MP grease to the sliding area of the rear door outside handle frame sub-assembly LH.

    2. B0027XWC01
      *a Grommet
      *b Guide
      B0069FO Install in this Direction

      Attach the grommet and guide to install the rear door outside handle frame sub-assembly LH as shown in the illustration.

    3. Using a T30 "TORX" socket wrench, install the screw.

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

  8. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B00293TC01
      B0069FO Install in this Direction

      Attach the claw to install the rear door rear outside handle pad.

  9. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B00287QC01
      B0069FO Install in this Direction

      Attach the claw to install the rear door front outside handle pad.

  10. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B0028NFC01
      B0069FO Install in this Direction

      Install the rear door outside handle assembly LH as shown in the illustration.

  11. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. B0027YYC01
      B0069FO Install in this Direction

      Attach the claw to install the rear door outside handle cover LH as shown in the illustration.

    2. Using a T30 "TORX" socket wrench, install the screw.

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

  12. INSTALL DOOR LOCK WIRING HARNESS SEAL

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  13. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

    Click here

  14. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH

    Click here

  15. INSTALL REAR DOOR LOCK COVER SUB-ASSEMBLY LH

    Click here

  16. INSTALL REAR DOOR LOCK ASSEMBLY LH

    Click here

  17. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH


    1. B002775

      Install the rear door lock child protection cover LH.

  18. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (w/ Power Window)

    Click here

  19. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding area of the rear door window regulator sub-assembly LH.

    2. Temporarily install the temporarily bolt to the rear door window regulator sub-assembly LH.

    3. w/ Power Window:


      1. Install the rear door window regulator sub-assembly LH with the 3 bolts and temporary bolt.

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

      2. Connect the connector.

    4. w/o Power Window:

      Install the rear door window regulator sub-assembly LH with the 2 bolts and temporary bolt.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Temporarily Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      B00258IC01
      *A w/o Power Window *B w/ Power Window
      B0068HS Bolt B006964 Connector
      B0069AV Temporarily Bolt - -

  20. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH


    1. B00265Z

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

  21. INSTALL REAR DOOR QUARTER WINDOW GLASS LH


    1. B0026QAC02
      *a Emboss
      B0069FO Install in this Direction

      Install the rear door quarter window glass LH together with the rear door quarter window weatherstrip LH as shown in the illustration.

      Tech Tips

      Make sure that the emboss on the rear door inner panel can be seen below rear door quarter window weatherstrip LH inner lip.

  22. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH

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  23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. B0025UIC01
      B0069FO Install in this Direction (1)
      B0068NX Install in this Direction (2)

      Insert the rear door glass sub-assembly LH as shown in the illustration.

    2. B0028BE

      Install the rear door glass sub-assembly LH to the rear door window regulator sub-assembly LH as shown in the illustration.

      Note

      Be careful not to damage the rear door glass sub-assembly LH.

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


    1. B0026JAC02
      B0068HS Bolt
      B006964 Screw

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

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

    2. Lift up the rear door weatherstrip LH and install the screw.

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

  25. INSTALL REAR DOOR GLASS RUN LH


    1. B0026K2

      Attach the guide to install a new rear door glass run LH.

  26. INSTALL SCREW GROMMET


    1. B0026EM

      Attach the claw to install 2 new screw grommets.

  27. INSTALL REAR DOOR SERVICE HOLE COVER LH


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

    2. B0025G6C01
      *a Reference Point

      Attach the clamp.

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

      Tech Tips


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

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

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

  28. INSTALL REAR SPEAKER ASSEMBLY

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  29. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. B0028AG

      Install a new rear door inner glass weatherstrip LH to the rear door trim board sub-assembly LH and fold down the claw in the directions indicated by the arrows in the illustration.

  30. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. B00288ZC01
      B0069FO Install in this Direction

      Attach the claw and guide to install the rear door inside handle sub-assembly LH to the rear door trim board sub-assembly LH.

  31. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B0027ZRC02
      *1 Rear Door Inside Locking Cable Assembly LH
      *2 Rear Door Lock Remote Control Cable assembly LH
      B0069FO Install in this Direction

      Attach the clamp to connect the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH as shown in the illustration.

    2. B00267VC01
      B0069FO Install in this Direction

      Attach the guide as shown in the illustration.

    3. B00280V

      Attach the clip to install the rear door trim board sub-assembly LH.

    4. B0026KF

      Install the 3 screws.

  32. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH


    1. B0027E5

      Attach the claw to install the rear door inside handle bezel plug LH.

  33. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/ Power Window)

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


    1. Connect the connector.

    2. B0024BXC01
      B0069FO Install in this Direction

      Attach the claw and clip to install the rear power window regulator switch assembly with rear door armrest base panel as shown in the illustration.

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


    1. B0024WDC02
      *1 Plate
      *a Front
      *b 30°

      With the door window fully closed, install the plate and rear door window regulator handle with the snap ring as shown in the illustration.

  36. INSTALL REAR ARMREST ASSEMBLY LH


    1. B0025I6C01
      B0069FO Install in this Direction

      Attach the claw and clip to install the rear armrest assembly LH.

  37. INSTALL REAR DOOR FRAME GARNISH LH


    1. B0025EQ

      Attach the clip and claw to install the rear door frame garnish LH.

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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