REAR DOOR > REASSEMBLY

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1. Clean the vehicle body surface.
   
   

   1. Using a heat light, heat the vehicle body surface.
      

      Heating Temperature 

      Item	Temperature
      Vehicle Body	40 to 60°C (104 to 140°F)

      NOTICE:

      Do not heat the vehicle body excessively.

   2. Wipe off any tape adhesive residue with cleaner.
      

2. Installation temperature
   
   

   1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.
      

      HINT:

      1. The most appropriate temperature for installing the tape is 25°C (77°F).
         
      2. When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases.
         

3. Before installation
   
   

   1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.
      

      HINT:

      Spray water on the shop floor to settle any dust.

4. Key points for handling the tape
   
   

   1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.
      

      NOTICE:

      Do not bend the tape or leave it in high temperature places.

5. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)
   

   NOTICE:

   1. Position the tape accurately to achieve a neat finish and to avoid peeling.
      
   2. The tape cannot be reused because it deforms and will not fit any more after being removed.
      
   
   
   
   
   

   1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 3 to 7 cm (1.18 to 2.76 in.) per second.
      
      

      
      
      
      
      

      Text in Illustration 

      *A	Pressing Forward	*B	Pulling
      *1	Non-padded Side	*2	Padded Side
      *3	Squeegee	*4	Black Out Tape
      *5	Release Paper	-	-
      *a	Side View	-	-

      Reference Measurement 

      Area	Measurement
      A	10 to 20 mm (0.393 to 0.787 in.)
      B	30 to 70 mm (1.18 to 2.76 in.)
      C	40 to 50° (for pressing forward)
      D	30 to 45° (for pulling)

      NOTICE:

      Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

      HINT:

      1. Either angle of the squeegee (pressing forward or pulling) is acceptable.
         
      2. Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.
         

6. Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces)
   
   

   
   
   

   1. If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.
      

      Text in Illustration 

      *1	Squeegee
      *2	Hem
      *a	First
      *b	Second
      *c	Third

      HINT:

      When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

7. Key points for installation of the tape (how to use a squeegee and installation procedure for corners)
   
   

   1. Remove the release paper and apply the tape carefully with your fingers.
      

   2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.
      

8. Check after installation
   
   

   1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.
      

      NOTICE:

      Do not reuse the tape.

1. Refer to the illustration to position a new rear door lower outside stripe.
   
   

   
   
   
   
   

   Text in Illustration 

   *A	LH Side	*B	RH Side
   *a	Edge of Curved Surface	*b	Straight
   *c	Cutout	-	-

   Standard Measurement 

   Dimension	Measurement
   A	1.5 mm (0.0591 in.)
   B	1.0 mm (0.0394 in.)

2. Remove the release paper and apply the stripe.
   

1. Refer to the illustration to position a new rear door outside stripe.
   
   

   
   
   
   
   

   Text in Illustration 

   *A	LH Side	*B	RH Side
   *a	Edge of Curved Surface	*b	Straight
   *c	Cutout	-	-

   Standard Measurement 

   Dimension	Measurement
   A	1.5 mm (0.0591 in.)
   B	1.0 mm (0.0394 in.)

2. Remove the release paper and apply the stripe.
   

1. Engage the guide and 2 claws, and install the rear door window frame moulding sub-assembly to the door frame.
   

2. Using an air riveter or hand riveter with a nose piece, install the rear door upper window frame moulding with 7 new rivets.
   

   HINT:

   If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

   NOTICE:

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

      Text in Illustration 

      *1	Riveter
      *2	Mandrel
      *a	Incorrect

   
   
   2. 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.
      

      Text in Illustration 

      *1	Riveter
      *a	Incorrect

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

      Text in Illustration 

      *1	Riveter
      *a	Incorrect

HINT:

When installing a new rear door front window frame moulding, heat the vehicle body and rear door front window frame moulding using a heat light.

NOTICE:

Do not heat the vehicle body or rear door front window frame moulding excessively.

1. Clean the vehicle body surface.
   
   

   1. Using a heat light, heat the vehicle body surface.
      

   2. Remove the double-sided tape from the vehicle body.
      

   3. Wipe off any tape adhesive residue with cleaner.
      

2. Install a new rear door front window frame moulding.
   

   Text in Illustration 

   *1	Double-sided Tape
   *2	Caulking Sponge

   
   

   1. Using a heat light, heat the vehicle body and rear door front window frame moulding.
      

   2. Remove the release paper from the rear door front window frame moulding.
      

      HINT:

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

   3. Install the rear door front window frame moulding with the clip.
      

HINT:

When installing a new No. 3 rear door weatherstrip, heat the vehicle body and No. 3 rear door weatherstrip using a heat light.

NOTICE:

Do not heat the vehicle body or No. 3 rear door weatherstrip excessively.

1. Using a heat light, heat the vehicle body surface.
   

   Heating Temperature 

   Item	Temperature
   Vehicle Body	40 to 60°C (104 to 140°F)
   No. 3 Rear Door Weatherstrip	20 to 30°C (68 to 86°F)

2. Remove the double-sided tape from the vehicle body.
   

3. Wipe off any tape adhesive residue with cleaner.
   

4. Install a new No. 3 rear door weatherstrip.
   

   Text in Illustration 

   *1	Double-sided Tape

1. Engage the 5 claws and guide to install the rear door belt moulding assembly as shown in the illustration.
   

1. Engage the claw and install a new rear door panel cushion.
   

1. Engage the 4 clips to install the No. 2 rear door weatherstrip.
   

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

2. 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 }

1. Engage the 2 claws and install the rear door rear outside handle pad.
   

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

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

   NOTICE:

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

1. 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 }

1. Install the rear door inside locking cable assembly.
   

2. Engage the 3 claws.
   

1. Install the rear door inside locking cable assembly.
   

2. Engage the 3 claws.
   

1. Install the rear door lock remote control cable assembly.
   

2. Engage the claw.
   

1. Install the rear door lock remote control cable assembly.
   

2. Engage the claw.
   

NOTICE:

1. When reusing the removed rear door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
   
2. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
   
3. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock assembly.
   

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

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

3. Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.
   

4. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.
   

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

   Torque:

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

NOTICE:

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

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

   Torque:

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

   HINT:

   When replacing the rear window regulator, a new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

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

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

3. Temporarily install the rear door window regulator assembly.
   

   Text in Illustration 

   *1	Temporary Bolt

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

   HINT:

   Tighten the bolts in the order shown in the illustration.

   Torque:

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

1. When reusing the rear door cushion:
   
   

   1. Clean the rear door cushion.
      

   2. Remove the double-sided tape from the rear door cushion.
      

   3. Wipe off any tape adhesive residue with cleaner.
      

   
   
   

   4. Apply new double-sided tape to the rear door cushion as shown in the illustration.
      

      Area	Dimension
      (A)	80.0 mm (3.150 in.)
      (B)	20.0 mm (0.787 in.)
      (C)	4.0 mm (0.157 in.)

2. Clean the rear door panel sub-assembly.
   

3. Engage the 2 guides.
   

   Text in Illustration 

   *1	Double-sided Tape

4. Install the rear door cushion with the 2 bolts.
   

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

2. Install the rear door glass channel filler to the position shown in the illustration.
   

   Text in Illustration 

   *A	Front Side
   *B	Rear Side
   *a	0 mm (0 in.)
   *b	0 mm (0 in.)
   *c	Edge of curved surface

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

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

   Text in Illustration 

   *A	Front Side
   *B	Rear Side
   *a	14.0 mm (0.551 in.)
   *b	11.0 mm (0.433 in.)
   *c	Edge of curved surface

   NOTICE:

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

1. Slide the rear door glass sub-assembly to install it as shown in the illustration.
   

1. Install the No. 2 rear door vent seal.
   

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

2. Install the rear door quarter window glass together with the rear door quarter window weatherstrip in the direction indicated by the arrow in the illustration.
   

1. Install the temporary bolt to the rear door window division bar sub-assembly.
   

2. Temporarily install the rear door window division bar sub-assembly.
   

   Text in Illustration 

   *1	Temporary Bolt

3. Install the bolt and screw.
   

   Torque:

   Bolt:

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

4. Tighten the temporary bolt to install the rear door window division bar sub-assembly.
   

   Torque:

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

1. Install the No. 1 rear door vent seal.
   

1. Install the rear door glass run.
   

1. Engage the 23 clips to install a new rear door weatherstrip.
   

   Text in Illustration 

   *1	Double-sided Tape

1. Apply MP grease to the sliding parts 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. Install the rear door check assembly with the 3 bolts.
   

   Torque:

   (A):

   27 N*m{ 275 kgf*cm , 20 ft.*lbf }

   (B):

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

1. Apply butyl tape to the rear door panel.
   

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

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

   Text in Illustration 

   *1	Reference Point

   NOTICE:

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

4. Connect the connector.
   

5. Engage the clamp.
   

1. Install the rear door trim bracket with the 2 screws.
   

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

1. Install the rear door speaker cover with the 3 bolts.
   

   HINT:

   Install the bolts in the order shown in the illustration.

2. Connect the connector.
   

1. Install the rear speaker assembly with the 3 bolts.
   

   NOTICE:

   Do not touch the speaker cone.

   HINT:

   Install the bolts in the order shown in the illustration.

2. Connect the connector.
   

1. Engage the 6 clips of the rear door trim seal.
   

1. Engage the 3 claws and install the rear door inner glass weatherstrip as shown in the illustration.
   

1. Engage the claw and 2 guides, and install the rear door inside handle sub-assembly to the rear door trim board sub-assembly as shown in the illustration.
   

1. Install a new rear door trim board clip (blue) to the rear door trim board.
   

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

   Text in Illustration 

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

3. Connect the connector.
   

4. Engage the rear door trim board sub-assembly with the 3 claws to the rear door inner glass weatherstrip as shown in the illustration.
   

5. Engage the 8 clips and temporarily install the rear door trim board sub-assembly.
   

6. Engage the clip <A> and install the rear door trim board sub-assembly.
   

7. Install the 2 screws.
   

8. Remove the protective tape.
   

1. Install the rear door armrest cover.
   

1. Connect the connector.
   

2. Engage the 2 guides, 3 clips and 4 claws, and install the rear power window regulator switch assembly with rear door armrest base panel.
   

1. Engage the 3 guides, clip and 3 claws, and install the rear door rear frame bracket.
   

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

NOTICE:

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

1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.
   

1. Engage the 6 guides.
   

2. Install the deck floor box RH with the clip.
   

1. Install the rear No. 3 floor board.
   

1. Install the rear deck floor box.
   

1. Install the rear No. 2 floor board.