REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.

PROCEDURE


  1. INSTALL REAR DOOR OUTSIDE STRIPE

    Click here

  2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

    Click here

  3. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

    Click here

  4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

    Click here

  5. INSTALL REAR DOOR OUTSIDE MOULDING

    Click here

  6. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  7. INSTALL REAR DOOR PANEL CUSHION


    1. B008KJU

      Engage the claws to install the 2 rear door panel cushions.

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

    Click here

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


    1. B008M81N01

      Engage the guides to temporarily install the rear door speaker cover.

    2. Using an air riveter or a hand riveter, install the front speaker cover with 3 new rivets in the order shown in the illustration.

      Note


      • B008KOSC26
        *a Riveter
        *b Mandrel
        *c Incorrect

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

      • B008L8CC09
        *a Riveter
        *b Incorrect

        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.

      • B008KZSC10
        *a Riveter
        *b Incorrect

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

    3. B008M2T

      Connect the connector.

  10. INSTALL REAR DOOR DUST PROOF SEAL


    1. B008K5H

      Install the 3 rear door dust proof seals.

  11. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

    Click here

  12. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. B008LMS

      Engage the guide to connect the No. 1 rear door lock remote control cable assembly.

    2. B008L43

      Engage the claws to install the rear door outside handle assembly.

    3. Install the 3 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. B008LRV

      Connect the No. 1 rear door lock remote control cable assembly to the clamps.

  13. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. Clean the rear door outside handle assembly surface.

    2. Remove the release paper from the face of the rear door outside handle cover.

    3. B008KFTC02
      B008MCV Double-sided Tape

      Engage the clips and guide to install a new rear door outside handle cover.

    4. Press the double-sided tape area of the rear door outside handle cover.

  14. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  15. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP


    1. B008LAJ

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

  16. INSTALL REAR DOOR QUARTER WINDOW GLASS


    1. B008K6BC01
      B008LJK Install in this Direction

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

  17. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY


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

    2. B008M0MC02
      *a Temporary Bolt

      Temporarily install the temporary bolt to the rear door window regulator sub-assembly.

    3. Temporarily install the rear door window regulator sub-assembly with the 3 bolts.

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

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    5. Connect the connector.

  18. INSTALL REAR DOOR GLASS RUN


    1. B008KA8

      Install the rear door glass run.

  19. INSTALL REAR DOOR FRAME GARNISH


    1. B008LUT

      Engage the guides to install the rear door frame garnish.

  20. INSTALL REAR DOOR GLASS CHANNEL FILLER (for LED Type Turn Signal Light)


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

    2. B008LA1C01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

      Install the rear door glass channel filler to the rear door glass sub-assembly at position shown in the illustration.

      Standard Dimension
      Area Measurement
      A 10 mm (0.394 in.)
      B 10 mm (0.394 in.)

  21. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY (for LED Type Turn Signal Light)


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

    2. B008KOYC01
      *A Front Side
      *B Rear Side
      *a Edge of curved surface

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

      Standard Dimension
      Area Measurement
      A 10 mm (0.394 in.)
      B 10 mm (0.394 in.)

      Note

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

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. B008LS9C01
      B008LJK Install in this Direction (1)
      B008KJ9 Install in this Direction (2)

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

      Note

      Do not damage the rear door glass sub-assembly.

    2. B008LJGC01
      B008LJK Install in this Direction

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

  23. INSTALL REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY


    1. B008LLG

      Temporarily install the rear door window rear lower frame sub-assembly with the 2 bolts.

    2. Install the screw.

    3. Tighten the 2 bolts.

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

    4. Connect the rear door glass run.

  24. INSTALL REAR DOOR WEATHERSTRIP


    1. Clean the rear door panel.

    2. Remove the release paper from a new rear door weatherstrip.

    3. B008KABC04
      *a Clip (A)
      B008MCV Double-sided Tape

      Engage the clip (A) and other clip to install the rear door weatherstrip.

    4. Press the double-sided tape area of the rear door weatherstrip.

  25. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole in the vehicle body.

    3. Clean the threads of the bolt (A).

    4. Apply adhesive to the threads of the bolt (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. B008KO0C01
      *a Bolt (A)
      *b Bolt (B)

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

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

  26. INSTALL REAR DOOR SERVICE HOLE COVER


    1. B008M8XC01
      *a Reference Point
      B008MFH Butyl Tape

      Apply new butyl tape to the rear door panel.

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

    3. Install the front door service hole cover according to the reference points on the front door panel.

      Note

      Securely install the rear door service hole cover preventing wrinkles and air bubbles.

  27. INSTALL REAR DOOR TRIM BRACKET


    1. B008L30

      Install the rear door trim bracket with the 2 screws.

  28. INSTALL NO. 2 REAR DOOR FRAME GARNISH


    1. B008LNT

      Install the No. 2 rear door frame garnish.

  29. INSTALL HOLE PLUG


    1. B008KJ4

      Install the 2 hole plugs.

  30. INSTALL REAR DOOR BELT SEAL


    1. B008LDNC01
      B008LJK Install in this Direction

      Install the rear door belt seal to the rear door glass inner weatherstrip as shown in the illustration.

  31. INSTALL REAR DOOR GLASS INNER WEATHERSTRIP


    1. B008KNPC01
      B008LJK Install in this Direction

      Install the rear door glass inner weatherstrip with the rear door belt seal as shown in the illustration.

  32. INSTALL REAR DOOR BELT REAR SEAL


    1. B008LJS

      Install the rear door belt rear seal.

  33. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B008LQC

      Engage the guides and claw to install the front door inside handle sub-assembly.

  34. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. B008KQXC01
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly
      B008LJK Install in this Direction

      Engage the guides to connect the rear door inside locking cable assembly and rear door lock remote control cable assembly.

    2. B008M68C01
      B008LJK Install in this Direction

      Engage the claws as shown in the illustration.

    3. B008MG4

      Engage the guide and clips to install the rear door trim board sub-assembly.

    4. Install the 2 screws.

    5. B008MES

      Install the 3 screws.

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


    1. B008M4T

      Connect the connector.

    2. B008KHSC01
      B008LJK Install in this Direction

      Engage the guides, clips and claws to install the rear power window regulator switch assembly with rear door armrest base upper panel as shown in the illustration.

  36. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. B008L9LC01
      B008LJK Install in this Direction

      Engage the claws to install the rear door inside handle bezel plug as shown in the illustration.

  37. INSTALL REAR DOOR REAR FRAME BRACKET


    1. B008LPZC01
      B008LJK Install in this Direction

      Engage the claws and clip to install the rear door rear frame bracket as shown in the illustration.

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    Note

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

    Click here

  39. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  40. INSPECT POWER WINDOW OPERATION

    Click here