Rear Door (Exterior Body Panels): Overhaul

HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
Use the same procedures on the RH side as on the LH side.

REMOVE POWER WINDOW REGULATOR SWITCH ASSY REAR
1. Using a screwdriver, disengage the 2 claws and 2 clips, and remove the inside handle bezel.
  HINT:
  
  Tape the screwdriver tip before use.
2. Disengage the 2 claws and remove the switch.
  
  Fig 1: Locating Claw And Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH
1. Using a screwdriver, disengage the 3 claws and remove the bezel plug.
HINT:

Tape the screwdriver tip before use.

Fig 2: Removing Rear Door Inside Handle Bezel Plug LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH
1. Remove the armrest cover.
2. Remove the 2 screws.
3. Using a clip remover, remove the 13 clips and remove the trim board.
  HINT:
  
  In order to prevent the door panel from being damaged, cover the areas indicated by arrow marks in the illustration with protective tape.
4. Disconnect the 2 cables from the inside handle.
  
  Fig 3: Disconnecting 2 Cables From Inside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR GLASS WEATHERSTRIP INNER LH
1. Remove the weatherstrip inner pulling it upward in the direction indicated by arrow mark in the illustration.
  
  Fig 4: Removing Weatherstrip Inner Pulling
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR BELT MOLDING ASSY LH (See REPLACEMENT )
REMOVE REAR DOOR WINDOW FRAME MOLDING SUB-ASSY LH (See REPLACEMENT )
REMOVE REAR DOOR ARMREST SET BRACKET LH
1. Remove 2 screws and armrest set bracket.
REMOVE REAR DOOR SERVICE HOLE COVER LH
1. Using a clip remover, disengage the clamps.
2. Remove the service hole cover.
NOTE: Remove the remaining tape on the door side.

Fig 5: Removing Service Hole Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH
HINT:

Insert a shop rag inside the door panel to prevent the glass from being scratched.

NOTE: Do not damage the door glass.
1. Remove the glass run.
2. Remove the 2 bolts, screw and division bar.
  
  Fig 6: Removing Division Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Rotate the division bar by 90° and pull it upward, as shown in the illustration.
  
  Fig 7: Rotating Division Bar By 90°
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR QUARTER WINDOW GLASS LH
1. Remove the window glass in the direction indicated by arrows as shown.
NOTE: Do not damage the glass.

Fig 8: Removing Rear Door Quarter Window Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP LH
REMOVE REAR DOOR GLASS SUB-ASSY LH
1. Carefully pull up the door glass out of the door panel.
HINT:

Insert a shop rag inside the door panel to prevent the door glass from being scratched.

Fig 9: Removing Rear Door Glass Sub-Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY LH
1. Disconnect the window regulator connector.
2. Remove the 3 bolts and window regulator.
NOTE: When the bolts are removed, the window regulator may fall and become deformed.

HINT:

Remove the window regulator through the service hole.

Fig 10: Removing Window Regulator Fasteners
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH
1. Place matchmarks on the regulator motor gear and regulator gear.
2. Using a Torx driver (T25), remove the 3 screws and regulator motor.
REMOVE REAR DOOR LOCK ASSY LH
1. Disconnect the door lock connector.
2. Using a Torx socket wrench (T30), remove the 3 screws and door lock.
HINT:

Remove the door lock through the service hole.

Fig 11: Removing Rear Door Lock Assy Fasteners
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR OUTSIDE HANDLE COVER LH
1. Using a Torx socket wrench (T30), loosen the screw and remove the outside handle cover.
  
  Fig 12: Removing Rear Door Outside Handle Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH
1. Pull and hold the release plate of the outside handle frame, as shown in the illustration.
  
  Fig 13: Removing Rear Door Outside Handle Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Pushing and pulling the outside handle in the direction indicated by arrow mark in the illustration, remove the handle.
  NOTE: If the release plate is not pulled and held when removing the outside handle, then the release plate will interfere with the outside handle and damage the release plate.
3. Remove the outside handle pads front and rear.
  
  Fig 14: Removing Outside Handle In The Direction Indicated
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
1. Using a Torx socket wrench (T30), loosen the screw.
2. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration and remove it.
  
  Fig 15: Removing Outside Handle Frame In The Direction Indicated
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:

Remove the outside handle frame through the service hole.
REMOVE REAR DOOR CHECK ASSY LH
1. Remove the check cover.
2. Remove the 2 nuts, bolt and door check.
HINT:

Remove the door check through the service hole.

Fig 16: Removing Door Check Fasteners
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR WEATHERSTRIP LH
1. Using a clip remover, disengage the clips and remove the weatherstrip.
HINT:

If the clip is damaged, replace it for a new clip.

Fig 17: Removing Rear Door Weatherstrip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR CHECK ASSY LH
1. Apply MP grease to the sliding and rotating areas of the door check.
2. Install the door check to the door panel with the 2 nuts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
  
  HINT:
  
  Install the door check so that the rivet head is up.
  
  Fig 18: Installing Check So That The Rivet Head Is Up
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply adhesive to the threads of the bolt.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
4. Install the door check to the body panel with the bolt.
  Torque: 27 N.m (275 kgf.cm, 20 ft.lbf)
5. Install the check cover.
INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
1. Install the open rod to the outside handle frame.
2. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration.
3. Using a Torx socket wrench (T30), install the outside handle frame with the screw.
  Torque: 7.0 N.m (71 kgf.cm, 62 in..lbf)
  
  NOTE: Insert a cover between the nut and the door panel.
4. Install the outside handle pads front and rear.
  
  Fig 19: Installing Outside Handle Pads Front And Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE ASSY LH
1. Pull and hold the release plate of the outside handle frame, as shown in the illustration.
  
  Fig 20: Holding Release Plate Of Outside Handle Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Pushing the outside handle in the direction indicated by the arrow mark in the illustration, install the outside handle.
NOTE: If the release plate is not pulled and held when installing the outside handle, the release plate will interfere with the outside handle. It will damage the release plate.

Fig 21: Installing Rear Door Outside Handle Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
1. Using a Torx socket wrench (T30), install the outside handle cover with the screw.
Torque: 7.0 N.m (71 kgf.cm, 62 in..lbf)

Fig 22: Installing Outside Handle Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR LOCK ASSY LH
1. Apply MP grease to the sliding and rotating areas of the door lock.
2. Install a new door lock wire harness packing.
  NOTE:
  - If reusing a removed door lock, replace the packing in the connecting part with a new packing.
  - Be careful that no grease and dirt sticks to the packing surface in the connecting part.
  - Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.
3. Engage the door with the release plate of the outside handle and then set it to the door panel.
  NOTE: Make sure that the release plate of the outside handle frame is securely engaged with the door lock.
4. Apply adhesive to the threads of the screws.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
5. Using a Torx socket wrench (T30), install the door lock with the 3 screws.
  Torque: 5.0 N.m (51 kgf.cm, 42 in..lbf)
6. Connect the door lock connector.
  
  Fig 23: Installing Rear Door Lock Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH
1. Using a Torx driver (T25), install the regulator motor with the 3 screws.
Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf)
INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSY LH
1. Apply MP grease to the sliding and rotating areas of the window regulator.
  NOTE: Do not apply grease to the spring of the window regulator.
  
  Fig 24: Applying MP Grease Sliding And Rotating Areas Of The Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the window regulator with the 3 bolts in the order as shown.
  Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
  
  NOTE: Be careful not to drop the rear door window regulator, as this may cause deformation.
3. Connect the window regulator connector.
  
  Fig 25: Installing Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR GLASS SUB-ASSY LH
NOTE: Be careful not to drop the glass, as this may cause deformation.
1. Install the door glass into the door panel.
HINT:

Insert a shop rag inside the door panel to prevent the door glass from being scratched.

Fig 26: Installing Rear Door Glass Into Door Panel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR QUARTER WINDOW GLASS LH
1. Install the quarter window weatherstrip on the glass.
  NOTE: Do not damage the glass.
2. Install the quarter window glass, as shown in the illustration.
  
  Fig 27: Installing Quarter Window Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH
1. Insert the division bar into the door panel, then rotate it by 90°, as shown in the illustration.
2. Mount the door glass to the window regulator.
3. Tighten the division bar with the 2 bolts and screw.
  Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf)
4. Install the glass run.
5. Reset the power window motor (See HOW TO PROCEED WITH TROUBLESHOOTING ).
6. Inspect operation of the power window.
HINT:

When the installation point of the door glass does not match, adjust the window regulator position in manual operation.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Repeat UP and DOWN operation several times in manual operation.
INSTALL REAR DOOR SERVICE HOLE COVER LH
1. Apply butyl tape to the door panel, as shown.
HINT:
- When installing the service hole cover, pull out the links and connectors through the service hole cover.
- There should be no wrinkles or folds after attaching the service hole cover.
- After attaching the service hole cover, confirm the sealing condition.
  
  Fig 30: Installing Rear Door Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002