REAR DOOR REASSEMBLY

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • 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 CHECK ASSEMBLY LH


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

    2. When reusing a bolt labeled B:


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

      2. Apply adhesive to the threads of the bolt labeled B.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. A01DWXKE01
      Text in Illustration
      *1 Bolt A
      *2 Bolt B

      Install the rear door check with the 2 bolts labeled A and bolt labeled B.

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

  2. INSTALL REAR DOOR WEATHERSTRIP LH

    Tech Tips

    When installing the rear door 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 weatherstrip.


      1. Remove the peeling paper from the face of the rear door weatherstrip.

        Tech Tips

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

      2. Attach the 32 clips to install the rear door weatherstrip.

        Tech Tips

        Press the rear door weatherstrip firmly to install it.

      3. Install the clip.

  3. INSTALL REAR DOOR PANEL CUSHION


    1. Install a new rear door panel cushion.

  4. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


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

  5. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


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

  6. 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. 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 }

  7. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A01DZYI

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

  8. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH


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

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

  9. 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.

  10. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the rear door lock remote control cable.

  11. INSTALL REAR DOOR LOCK ASSEMBLY LH


    1. w/ Power Door Lock:


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

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      2. Connect the rear door inside locking cable and rear door lock remote control cable to the clamps.

      3. Connect the connector.

    2. w/o Power Door Lock:


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

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      2. Connect the rear door inside locking cable and rear door lock remote control cable to the clamps.

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


    1. Using a T25 "TORX" socket wrench, install the power window regulator motor with the 3 screws.

  13. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. A01E287E01
      Text in Illustration
      *A w/ Power Window
      *B w/o Power Window

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

      Note

      Do not apply grease to the spring of the window regulator.

    2. A01DXUEE01
      Text in Illustration
      *1 Temporary Bolt

      w/ Power Window:


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

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

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

        Note

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

      3. Connect the connector.

    3. A01E0R3E01
      Text in Illustration
      *1 Temporary Bolt

      w/o Power Window:


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

      2. Install the rear door window regulator with the 2 bolts, and then tighten the temporary bolt.

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

        Note

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

  14. INSTALL REAR DOOR GLASS CHANNEL FILLER


    1. A01DZNIE01
      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 10.7 mm (0.421 in.)

  15. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH


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

    2. A01DW68E01
      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.

      Note

      Be careful not to damage the glass or glass channel.

      Standard
      Area Dimension
      A 10.7 mm (0.421 in.)

  16. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH


    1. w/ Power Window:


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

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

    2. w/o Power Window:


      1. Temporarily install the rear door window regulator handle.

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

      3. Remove the rear door window regulator handle.

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

    4. A01DXVWE01
      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 155 mm (6.10 in.)
      B 30 mm (1.18 in.)
    5. A01DZTXE01
      Text in Illustration
      *a Rear Door Panel Cutout

      Install the rear door glass by passing it through the cutout of the rear door panel in the direction indicated by the arrow in the illustration.

      Note

      Do not damage the door glass.

    6. A01E0IC

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

      Note

      Do not damage the door glass.

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


    1. Align the rear door glass run with the rear door window division bar.

    2. Install the rear door glass run together with the rear door window division bar with the 2 bolts.

  18. INSTALL REAR DOOR GLASS RUN LH


    1. Finish installing the rear door glass run.

  19. INSTALL REAR DOOR SERVICE HOLE COVER LH


    1. A01E2LZE01
      Text in Illustration
      *a Reference Point

      w/ Rear Speaker:


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

      2. Pass the rear door inside locking cable, rear door lock remote control cable and wire harness 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.

    2. A01E1O0E01
      Text in Illustration
      *a Reference Point

      w/o Rear Speaker:


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

      2. 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.

  20. INSTALL REAR DOOR NO. 2 TRIM BRACKET


    1. Install the rear door No. 2 trim bracket with the 2 screws.

  21. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH


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

    2. A01E1R1

      Attach the 2 guides as indicated by the arrow in the illustration, and then attach the claw to install the rear door inside handle.

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


    1. Install a nose piece to an air riveter or hand riveter. Then insert the mandrel part of a new φ4 mm waterproof rivet into the nose piece.

    2. A01E09B

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

      Note


      • A01DXR8E19

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

        Text in Illustration
        *1 Mandrel
        *2 Riveter
        *a INCORRECT
        *b CORRECT
      • A01DZ88E19

        Confirm that the rivets are seated properly against the speaker.

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

      • Do not tilt the riveter when installing the rivet to the speaker.

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

      • A01E0OHE17

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

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

    3. Connect the connector.

  23. INSTALL REAR DOOR OUTER GLASS WEATHERSTRIP LH


    1. Attach the 4 claws to install the rear door outer glass weatherstrip.

  24. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH


    1. A01E0QF

      Install the rear door inner glass weatherstrip to the rear door trim panel and fold down the 6 claws in the directions indicated by the arrows in the illustration.

  25. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH


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

    2. Install the screw and clip.

  26. INSTALL DOOR PULL HANDLE


    1. Install the door pull handle with the screw.

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


    1. Connect the connector.

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

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


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

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

    3. A01DY7PE01
      Text in Illustration
      *1 Snap Ring
      *2 Plate
      *a Front Side

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

      Standard
      Area Specified Condition
      A 18 to 42°

  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/ Power Window)

    Note

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