Reassembly [08/2013 - ]

WARNING: This page is about a different car, the 2014 Lexus ES 300h. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Use the same procedure for both the RH and LH sides.
The procedure described below is for the LH side.

PRECAUTION
NOTE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work. Refer to PRECAUTION [08/2013 - ] .
REPAIR INSTRUCTION . Refer to INSTALLATION [08/2013 - ] - Step 2
INSTALL FRONT INNER BLACK OUT TAPE . Refer to INSTALLATION [08/2013 - ] - Step 3
INSTALL REAR INNER BLACK OUT TAPE . Refer to INSTALLATION [08/2013 - ] - Step 4
INSTALL REAR DOOR WINDOW FRAME MOLDING SUB-ASSEMBLY . Refer to INSTALLATION [08/2013 - ] - Step 1
INSTALL REAR DOOR FRONT WINDOW FRAME MOLDING . Refer to INSTALLATION [08/2013 - ] - Step 2
INSTALL REAR DOOR NO. 3 WEATHERSTRIP
1. Clean the rear door panel.
2. Install a new rear door No. 3 weatherstrip.
  
  Fig 1: Identifying Rear Door No. 3 Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Double-sided Tape
INSTALL REAR DOOR BELT MOLDING ASSEMBLY . Refer to INSTALLATION [08/2013 - ] - Step 2
INSTALL CURTAIN HOOK (w/ Rear Door Sunshade)
1. Engage the 4 claws and install the 2 curtain hooks.
  
  Fig 2: Installing Curtain Hook (W/ Rear Door Sunshade)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 2 pins as shown in the illustration.
INSTALL REAR DOOR PANEL CUSHION
1. Engage the claw to install a new rear door panel cushion.
  
  Fig 3: Identifying Rear Door Panel Cushion
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR NO. 2 WEATHERSTRIP
1. Engage the 5 clips to install the rear door No. 2 weatherstrip.
  
  Fig 4: Identifying Rear Door No. 2 Weatherstrip Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY
1. Engage the 2 guides.
  
  Fig 5: Identifying Rear Door Inside Panel Reinforce Sub-Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rear door inside panel reinforce sub-assembly with the 3 screws.

INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

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

Engage the claw.

Fig 6: Applying MP Grease To Sliding Areas Of Lock

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*a	Outside
*b	Inside

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)
Engage the clamp.

Fig 7: Identifying Rear Door Outside Handle Frame Sub-Assembly Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD
1. Engage the 2 claws to install the rear door rear outside handle pad.
  
  Fig 8: Identifying Rear Door Rear Outside Handle Pad Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD
1. Engage the 3 claws to install the rear door front outside handle pad.
  
  Fig 9: Identifying Rear Door Front Outside Handle Pad
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY
1. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly.
  
  Fig 10: Rear Door Outside Handle Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  If the bellcrank lever is not pulled and held when installing the outside handle sub-assembly, 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 sub-assembly. 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.
  
  Fig 11: Rear Door Outside Handle Assembly Lever
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the connector.
  
  Fig 12: Identifying Rear Door Outside Handle Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Engage the 2 claws.
INSTALL REAR DOOR OUTSIDE HANDLE COVER
1. Engage the claw.
  
  Fig 13: Identifying Rear Door Outside Handle Cover Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY
1. Install the rear door inside locking cable assembly as shown in the illustration.
  
  Fig 14: Installing Rear Door Inside Locking Cable Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 3 claws as shown in the illustration.
  
  Fig 15: Installing Rear Door Inside Locking Cable Assembly Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
1. Install the rear door lock remote control cable assembly as shown in the illustration.
  
  Fig 16: Installing Rear Door Lock Remote Control Cable Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the claw as shown in the illustration.
  
  Fig 17: Installing Rear Door Lock Remote Control Cable Assembly Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR LOCK ASSEMBLY
NOTE:
- When reusing the removed rear door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
- Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
- 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. When reusing the rear door lock assembly:
  1. Install a new door lock wiring harness seal to the rear door lock assembly.
    
    Fig 18: Identifying Rear Door Lock Wiring Harness Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.
  
  Fig 19: Identifying Rear Door Lock Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Release Plate
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: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
INSTALL REAR 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. Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.
  
  Fig 20: Identifying Rear Power Window Regulator Motor Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY
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.
  
  Fig 21: Identifying Rear Door Window Regulator Assembly Bolt Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Temporary Bolt
4. Tighten the temporary bolt and 3 bolts to install the rear door window regulator assembly.
  Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
  
  HINT:
  
  Tighten the bolts in the order shown in the illustration.
5. Connect the connector.
6. Connect the cable to the auxiliary battery negative (-) terminal
7. Connect the rear power window regulator switch assembly.
8. Operate the rear power window regulator switch assembly to lower the rear door window regulator assembly to the lowest position.
9. Disconnect the rear power window regulator switch assembly.
10. Disconnect the cable from the auxiliary battery negative (-) terminal.

INSTALL REAR DOOR GLASS CHANNEL FILLER

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

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

Fig 22: Identifying Rear Door Glass Channel Filter Edge Of Curved Surface Dimension

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*A	Front Side
*B	Rear Side
*a	Edge of curved surface

Standard Dimension

Area	Measurement
A	10.0 mm (0.394 in.)
B	10.0 mm (0.394 in.)

INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY

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

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

Fig 23: Identifying Rear Door Glass Channel Sub-Assembly Filter Edge Of Curved Surface Dimension

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*A	Front Side
*B	Rear Side
*a	Edge of curved surface

Standard Dimension

Area	Measurement
A	15.0 mm (0.591 in.)
B	14.2 mm (0.559 in.)

NOTE:

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

INSTALL REAR DOOR GLASS ASSEMBLY
1. Slide the rear door glass assembly to install it as shown in the illustration.
  
  Fig 24: Identifying Rear Door Glass Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR QUARTER WINDOW GLASS
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.
  
  Fig 25: Identifying Rear Door Quarter Window Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY
1. Install the rear door lower window frame sub-assembly with the screw and 2 bolts.
  
  Fig 26: Identifying Rear Door Lower Window Frame Sub-Assembly Bolts And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt
  
  Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
INSTALL REAR DOOR NO. 1 VENT SEAL
1. Install the rear door No. 1 vent seal.
  
  Fig 27: Identifying Rear Door No. 1 Vent Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR GLASS RUN
1. Install the rear door glass run.
  
  Fig 28: Identifying Rear Door Glass Run
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR FRAME GARNISH
1. Engage the 3 claws to install the rear door frame garnish.
  
  Fig 29: Identifying Rear Door Frame Garnish Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR WEATHERSTRIP
1. Clean the rear door panel.
2. Engage the 22 clips and guide to install a new rear door weatherstrip.
  
  Fig 30: Identifying Rear Door Weatherstrip Clips And Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Double-sided Tape

INSTALL REAR DOOR CHECK ASSEMBLY

Apply MP grease to the sliding parts of the rear door check assembly.
Apply adhesive to the threads of the bolt.
Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the rear door check assembly with the 3 bolts.

Fig 31: Identifying Rear Door Check Assembly Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Bolt (A)
*2	Bolt (B)

Bolt (A)

Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)

Bolt (B)

Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

INSTALL REAR DOOR SERVICE HOLE COVER
1. Apply new 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.
  
  Fig 32: Installing Rear Door Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Reference Point
3. 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. Engage the 2 clamps.
5. Connect the connector.
INSTALL REAR DOOR ARMREST SET BRACKET
1. Install the rear door armrest set bracket with the 2 screws.
  
  Fig 33: Identifying Rear Door Armrest Set Bracket Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR SPEAKER ASSEMBLY . Refer to INSTALLATION [08/2013 - ] - Step 2
INSTALL REAR SIDE CURTAIN ASSEMBLY (w/ Rear Door Sunshade)
1. Engage the 2 claws and 2 clips and install the rear side curtain assembly.
  
  Fig 34: Installing Rear Side Curtain Assembly (W/ Rear Door Sunshade)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR INNER GLASS WEATHERSTRIP
1. Install the rear door inner glass weatherstrip.
  
  Fig 35: Identifying Rear Door Inner Glass Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 15 Speakers) . Refer to INSTALLATION [08/2013 - ] - Step 1
INSTALL REAR DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel and Bamboo Panel)
1. Engage the claw.
  
  Fig 36: Identifying Rear Door Trim Ornament Assembly Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the rear door trim ornament sub-assembly with the screw.
3. Install the rear door trim ornament assembly with the 11 screws.
  
  Fig 37: Identifying Rear Door Trim Ornament Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. w/ Illumination:
  1. Engage the 3 clamps.
    
    Fig 38: Identifying Rear Door Trim Ornament Sub-Assembly Clamps
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Engage the 2 guides and claw to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.
  
  Fig 39: Identifying Rear Door Inside Handle Sub-Assembly Claw And Guides
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

Install the No. 1 door scuff plate clamp as shown in the illustration.

Fig 40: Rear Door Trim Board Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*a Reference Point

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

Fig 41: Identifying Rear Door Lock Remote Control And Rear Door Inside Locking Cable Assemblies

TEXT IN ILLUSTRATION

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

w/ Illumination:
1. Connect the connector.
for 15 Speakers:
1. Connect the connector.

Engage the rear door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

Fig 42: Identifying Rear Door Trim Board Sub-Assembly Reference Boss

TEXT IN ILLUSTRATION

*1	Reference Boss
*2	Rear Door Inner Glass Weatherstrip

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

Fig 43: Identifying Rear Door Trim Board Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 3 screws.

Fig 44: Identifying Rear Door Trim Board Sub-Assembly Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION [08/2013 - ] - Step 3
INSTALL REAR DOOR NO. 1 STIFFENER CUSHION
1. Install the rear door No. 1 stiffener cushion with the screw.
  
  Fig 45: Identifying Remove Rear Door No. 1 Stiffener Cushion Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DOOR PULL HANDLE COVER
1. Install the door pull handle cover.
  
  Fig 46: Identifying Door Pull Handle Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL
1. Connect the connector.
2. Engage the 2 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.
  
  Fig 47: Identifying Rear Power Window Regulator Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG
1. Engage the 3 claws to install the rear door inside handle bezel plug.
  
  Fig 48: Installing Rear Door Inside Handle Bezel Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION [08/2013 - ]
INSTALL LUGGAGE TRIM SERVICE HOLE COVER . Refer to INSTALLATION [08/2013 - ] - Step 3
INITIALIZE POWER WINDOW CONTROL SYSTEM
Refer to INITIALIZATION [08/2013 - ]
INSPECT POWER WINDOW OPERATION
Refer to OPERATION CHECK [08/2013 - ]