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. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work Click here.

  2. REPAIR INSTRUCTION

    Click here

  3. INSTALL NO. 2 BLACK OUT TAPE

    Click here

  4. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

    Click here

  5. INSTALL REAR DOOR UPPER OUTSIDE STRIPE

    Click here

  6. INSTALL REAR DOOR OUTSIDE STRIPE

    Click here

  7. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

    Click here

  8. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

    Click here

  9. INSTALL REAR DOOR FRAME GARNISH (w/o Rear Door Sunshade)


    1. A005D6Z

      Engage the clip to install a new rear door frame garnish.

  10. INSTALL REAR DOOR NO. 2 FRAME GARNISH (w/o Rear Door Sunshade)


    1. A005B42

      Engage the clip to install a new rear door No. 2 frame garnish.

  11. INSTALL REAR DOOR FRAME GARNISH (w/ Rear Door Sunshade)


    1. A005EEX

      Engage the clip to install a new rear door frame garnish.

  12. INSTALL REAR DOOR NO. 2 FRAME GARNISH (w/ Rear Door Sunshade)


    1. A005EB3

      Engage the clip to install a new rear door No. 2 frame garnish.

  13. INSTALL REAR DOOR PANEL CUSHION


    1. A005DZS

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

  14. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. A005D1BE01
      Text in Illustration
      *a Outside
      *b Inside

      Engage the door handle nut and claw.

    3. Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly with the screw.

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

  15. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A005CQY

      Engage the 2 claws to install the rear door rear outside handle pad.

  16. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A005CZW

      Engage the 3 claws to install the rear door front outside handle pad.

  17. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A005COG

      Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.

      Note

      If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and the release plate will be damaged.

    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame. Next, slide the rear door outside handle assembly toward the front of the vehicle to install it.

    3. A005AVJ

      Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

  18. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A005E5L

      Engage the claw and install the rear door outside handle cover.

    2. 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 }

  19. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)


    1. A0059SB

      Install the rear door inside locking cable assembly as shown in the illustration.

  20. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)


    1. A005EIM

      Install the rear door inside locking cable assembly as shown in the illustration.

    2. A005A2E

      Engage the 3 claws as shown in the illustration.

  21. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)


    1. A005D2I

      Install the rear door lock remote control cable assembly as shown in the illustration.

  22. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)


    1. A005B4N

      Install the rear door lock remote control cable assembly as shown in the illustration.

    2. A005E7Q

      Engage the claw as shown in the illustration.

  23. INSTALL REAR DOOR LOCK COVER SUB-ASSEMBLY (w/o Double Locking System)


    1. A005D80

      Engage the 2 claws.

    2. A005E6X

      Engage the 2 claws to install the rear door lock cover sub-assembly as shown in the illustration.

  24. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

    Note


    • When reusing a removed rear door lock with motor assembly, replace the door lock wiring harness seal with a new one.

    • Do not allow grease or dust to adhere to the door lock wiring harness seal installation surface.

    • Reusing a door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water ingress. This may result in a malfunction of the rear door lock with motor assembly.


    1. Apply MP grease to the sliding parts of the rear door lock with motor assembly.

    2. When reusing the rear door lock with motor assembly:


      1. A005D2Q

        Install a new door lock wiring harness seal to the rear door lock with motor assembly.

    3. A005C9YE04
      Text in Illustration
      *a Release Plate

      Connect the rear door lock with motor assembly to the release plate of the rear door outside handle frame sub-assembly, and set it to the rear door panel.

    4. Make sure that the release plate of the rear door outside handle frame sub-assembly is securely connected to the rear door lock with motor assembly.

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

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

  25. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.


    1. A005CK1

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      A new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  26. INSTALL REAR DOOR POWER WINDOW REGULATOR ASSEMBLY


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

    2. Install the temporary bolt to the rear door power window regulator assembly.

    3. A0059SRE01
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install rear door power window regulator assembly.

    4. Tighten the temporary bolt and 5 bolts.

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

  27. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. Connect the cable to the negative (-) auxiliary battery terminal.

    2. Connect the rear power window regulator motor connector and power window regulator switch assembly, and move the rear door glass sub-assembly so that the door glass bolts can be seen.

    3. Disconnect the power window regulator switch assembly and rear power window regulator motor connector.

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

    5. A0059RI

      Insert the rear door glass sub-assembly into the rear door panel along the rear door glass run as shown in the illustration.

    6. Install the rear door glass sub-assembly with the 2 bolts.

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

  28. INSTALL REAR DOOR REAR GUIDE SEAL


    1. Install the rear door rear guide seal as shown in the illustration.

      A005BJM

    2. Install the 3 screws.

  29. INSTALL REAR DOOR WINDOW GUIDE SUB-ASSEMBLY


    1. A005D6L

      Install the rear door window guide sub-assembly with the screw and bolt.

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

  30. INSTALL REAR DOOR GLASS RUN


    1. A005AIR

      Install the rear door glass run.

  31. INSTALL REAR DOOR WEATHERSTRIP


    1. A005B0L

      Engage the 20 clips and install the rear door weatherstrip.

  32. INSTALL REAR DOOR CHECK ASSEMBLY


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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A0059V1

      Install the rear door check assembly with the bolt and 2 nuts.

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

  33. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

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

    3. A005BQTE01
      Text in Illustration
      *1 Reference Point

      Attach the rear door service hole cover according to the reference points on the rear door panel.

      Note

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

    4. Connect the 2 connectors.

  34. INSTALL REAR DOOR TRIM BRACKET


    1. A005A3X

      Install the rear door trim bracket with the 2 screws.

  35. INSTALL REAR SPEAKER ASSEMBLY

    Click here

  36. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 8 Speakers)

    Click here

  37. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A005EUO

      Engage the 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

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


    1. A005BEQ

      Install the rear curtain sub-assembly with the 9 screws.

  39. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A005AFS

      Engage the 7 claws to install the rear door inner glass weatherstrip to the rear door trim board sub-assembly as shown in the illustration.

  40. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A005EM0E01
      Text in Illustration
      *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 to the rear door inside handle sub-assembly.

    2. for 8 Speakers:


      1. Connect the connector.

    3. A005AMK

      Engage the 9 clips and install the rear door trim board sub-assembly.

    4. Install the 2 screws.

    5. If protective tape has been applied, remove it.

  41. INSTALL REAR DOOR ARMREST COVER


    1. A005EPR

      Install the rear door armrest cover.

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


    1. Connect the connector.

    2. A005CGV

      Engage the 5 guides, 10 claws and clip to install the rear power window regulator switch assembly with rear door armrest base panel.

  43. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A005A2T

      Engage the 3 claws to install the rear door inside handle bezel plug.

  44. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  45. INSTALL DECK FLOOR BOX RH

    Click here

  46. INSTALL REAR DECK FLOOR BOX

    Click here

  47. INSTALL NO. 1 DECK BOARD

    Click here

  48. INSTALL NO. 2 DECK BOARD

    Click here

  49. INSTALL DECK BOARD ASSEMBLY

    Click here

  50. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  51. INSPECT POWER WINDOW OPERATION

    Click here