REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedures for both the LH and RH sides.

  • The procedure described below is for the LH side.

PROCEDURE


  1. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

    Click here

  2. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  3. INSTALL REAR DOOR FRONT BELT MOULDING END COVER

    Click here

  4. INSTALL REAR DOOR WEATHERSTRIP


    1. B002D8P

      Engage the clips to install the rear door weatherstrip.

  5. INSTALL REAR DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole on the vehicle body.

    3. Clean the threads of the bolt.

    4. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    5. B002E8D

      Install the rear door check assembly 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. B002EBF

      Install a new rear door panel cushion.

  7. INSTALL REAR DOOR DUST PROOF SEAL


    1. B002DIT

      Engage the claw to install a new rear door dust proof seal.

  8. INSTALL NO. 3 REAR DOOR WEATHERSTRIP


    1. Clean vehicle installation surface.

    2. B002E2AC01
      *a Double-sided Tape

      Install a new No. 3 rear door stiffener cushion.

      Tech Tips

      Peel off the backing paper from the double-sided tape before installing the No. 3 rear door stiffener cushion.

  9. INSTALL NO. 2 REAR DOOR WEATHERSTRIP


    1. B002CZP

      Engage the clips to install the No. 2 rear door weatherstrip.

  10. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. B002D35C01
      B002C8N Install in this Direction

      Install the rear door outside handle frame sub-assembly 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 }
    4. B002DC8

      Engage the clamp.

  11. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B002CVGC01
      B002C8N Install in this Direction

      Engage the claws to install the rear door rear outside handle pad as shown in the illustration.

  12. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B002DKIC01
      B002C8N Install in this Direction

      Engage the claws to install the rear door front outside handle pad as shown in the illustration.

  13. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


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

    2. B002CPUC01
      B002C8N Install in this Direction

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

    3. B002DSQC01
      *a Holder
      B002C8N Install in this Direction

      Engage the holder as shown in the illustration.

    4. B002E70

      Connect the connector.

    5. B002CQDC01
      B002C8N Install in this Direction

      Engage the claws of the connector cover to connect the connector cover.

  14. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. B002EO0C01
      B002C8N Install in this Direction

      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

    Click here

  16. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

    Click here

  17. INSTALL REAR DOOR LOCK ASSEMBLY

    Click here

  18. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY


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

    2. B002F0LC01
      *a Temporary Bolt

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

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

    4. Install the rear door window regulator sub-assembly with the 4 bolts.

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

  19. INSTALL REAR DOOR BELT MOULDING

    Click here

  20. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. B002CJYC01
      *a Front Side

      Install a new rear door glass channel filler to the rear door glass sub-assembly as shown in the illustration.

      Standard
      Area Dimension
      A 12.0 mm (0.472 in.)
  21. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY


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

    2. B002DEWC01
      *a Front Side

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

      Standard
      Area Dimension
      A 21.0 mm (0.827 in.)
  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. Connect the power window regulator switch assembly.

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

    3. Move the rear door glass sub-assembly so that the door glass bolts can be seen.

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

    5. Disconnect the power window regulator switch assembly.

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

    7. B002EHQC01
      *a MP Grease

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

      Standard
      Area Dimension
      A 122.0 mm (4.803 in.)
      B 35.0 mm (1.378 in.)
    8. B002DXJ

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

      Note

      Do not damage the rear door glass sub-assembly.

  23. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP


    1. B002CX4

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

  24. INSTALL REAR DOOR QUARTER WINDOW GLASS


    1. B002DN9C01
      B002C8N Install in this Direction

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

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


    1. B002CV0

      Align the rear door glass run with the rear door window rear lower frame sub-assembly.

    2. B002DTV

      Insert the rear door window rear lower frame sub-assembly together with the rear door glass run into the rear door panel sub-assembly.

    3. Raise up the rear door weatherstrip and then install the screw.

    4. B002CCV

      Partially install the screw and 2 bolts.

    5. Install the rear door weatherstrip.

  26. INSTALL REAR DOOR GLASS RUN


    1. B002CGS

      Finish installing the rear door glass run.

  27. INSTALL REAR DOOR SERVICE HOLE COVER


    1. B002C61C02
      *1 Butyl Tape
      *a Reference Point

      Apply new butyl tape to the rear door panel sub-assembly.

    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 rear door service hole cover according to the reference points on the rear door panel sub-assembly.

      Note

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

  28. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  29. INSTALL REAR NO. 2 SPEAKER ASSEMBLY

    Click here

  30. INSTALL REAR DOOR ARMREST SET BRACKET


    1. B002CH6

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

  31. INSTALL REAR DOOR FRAME GARNISH


    1. B002CCP

      Engage the clips to install the rear door frame garnish.

  32. INSTALL REAR DOOR GLASS INNER WEATHERSTRIP


    1. B002CV6C01
      B002C8N Install in this Direction

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

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


    1. B002EE8

      Engage the claws and clips to install the rear side curtain assembly.

  34. INSTALL REAR DOOR TRIM COVER


    1. B002ELL

      Engage the clips to install the rear door trim cover.

  35. INSTALL NO. 1 REAR DOOR STIFFENER CUSHION


    1. B002CXI

      Install the No. 1 rear door stiffener cushion.

  36. INSTALL REAR DOOR TRIM SEAL


    1. B002DIU

      Engage the clips to install the rear door trim seal.

  37. INSTALL REAR DOOR COURTESY LIGHT ASSEMBLY

    Click here

  38. INSTALL REAR DOOR TRIM ORNAMENT SUB-ASSEMBLY


    1. B002CSO

      Engage the claws to install the rear door trim ornament sub-assembly from the No. 1 interior illumination light assembly.

  39. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B002CBF

      Engage the claw to install the rear door inside handle sub-assembly.

    2. Install the screw.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }
    3. B002E5L

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

  40. INSTALL REAR DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY

    Click here

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


    1. B002CMS

      Install the rear curtain sub-assembly with the 7 screws.

  42. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. B002C98C01
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly

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

    2. Connect each connector.

    3. B002C8TC01
      *a Reference Boss

      Engage the 3 claws to install the rear door trim board sub-assembly to the rear door glass inner weatherstrip.

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

    5. B002DBPC01
      *a Screw A

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

    6. Install the 3 screws.

      Torque:
      Screw A
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }
  43. INSTALL REAR ARMREST BASE UPPER PANEL SUB-ASSEMBLY


    1. Connect the connector.

    2. B002D31

      Engage the clips and claws to install the rear armrest base upper panel sub-assembly.

  44. INSTALL REAR DOOR HOLE COVER


    1. B002DJF

      Install the rear door hole cover.

  45. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. B002F05C01
      B002C8N Install in this Direction

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

  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

    Note

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

    Click here

  47. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  48. CHECK POWER WINDOW CONTROL SYSTEM

    Click here