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Home >> Toyota >> 2016 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 122 ((Door / Hatch) (Service Information) (Hybrid) (2 Of 2)) >> Rear Door >> Reassembly [02/2014 - 11/2015] >> Procedure

Reassembly [02/2014 - 11/2015]: Procedure

WARNING: This page is about a different variant/trim than selected.
  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 notices before proceeding with work.

    Refer to PRECAUTION [02/2014 - 11/2016]

  2. INSTALL REAR DOOR UPPER OUTSIDE MOULDING PAD 

    Refer to PROCEDURE - Step 1

  3. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. INSTALL REAR DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 6 clips to install the rear door No. 2 weatherstrip.
      GTY450558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 OUTSIDE MOULDING RETAINER 
    1. Engage the clip to install the No. 1 outside moulding retainer.
      GTY450556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the screw.
      GTY424522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 OUTSIDE MOULDING RETAINER 
    1. Engage the 2 clips to install the 2 No. 1 outside moulding retainers.
      GTY424521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 clips as shown in the illustration.
      GTY424524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  8. REPAIR INSTRUCTION 

    Refer to PROCEDURE - Step 1

  9. INSTALL UPPER INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 2

  10. INSTALL REAR INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 3

  11. INSTALL FRONT INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 4

  12. INSTALL REAR DOOR NO. 3 WEATHERSTRIP 
    1. Clean the rear door panel.
    2. Engage the claw and install a new rear door No. 3 weatherstrip.
      GTY455831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  13. INSTALL REAR DOOR REAR UPPER OUTSIDE MOULDING 

    Refer to PROCEDURE - Step 1

  14. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 2

  15. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  16. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 4

  17. INSTALL REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 1

  18. INSTALL REAR DOOR LOWER HOLE COVER 
    1. Install the rear door lower hole cover as shown in the illustration.
      GTY442295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR DOOR VENT SEAL 
    1. Clean the rear door panel.
    2. Install a new rear door vent seal as shown in the illustration.
      GTY430569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  20. INSTALL REAR DOOR PANEL CUSHION 
    1. Engage the 2 claws to install 2 new rear door panel cushions.
      GTY450557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL REAR DOOR FRAME GARNISH (w/o Rear Door Sunshade) 
    1. Engage the 3 claws to install the rear door frame garnish.
      GTY424531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL REAR DOOR FRAME GARNISH (w/ Rear Door Sunshade) 
    1. Engage the 3 claws to install the rear door frame garnish.
      GTY450559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL REAR DOOR CUSHION 
    1. Clean the rear door panel.
    2. Engage the 2 guides.
      GTY437335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
    3. Install a new rear door cushion with the 2 bolts.
  24. 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. Engage the claw.
      GTY434883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Outside
      *B Inside
    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) 

  25. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the rear door rear outside handle pad.
      GTY424536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the rear door front outside handle pad.
      GTY450560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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.
      GTY424535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the release plate of the rear door outside handle frame sub-assembly is not pulled and held when installing the rear door outside handle assembly, it will interfere with the rear door outside handle assembly and will be damaged.

    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly, then slide the rear door outside handle assembly toward the front of the vehicle to install it.
  28. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the claw.
      GTY424505Courtesy 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) 

  29. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the rear door inside locking cable assembly as shown in the illustration.
      GTY450553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the rear door lock remote control cable assembly as shown in the illustration.
      GTY424506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 claws as shown in the illustration.
      GTY424508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. 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. Install a new door lock wiring harness seal to the rear door lock with motor assembly.
        GTY424510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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.
      GTY424547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Release Plate

      HINT: 

      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.

    4. 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) 

  32. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    NOTE:

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

    1. Using a T25 "TORX" socket wrench, install the power window regulator motor assembly with the 3 screws.
      GTY424376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      HINT: 

      When replacing a power window regulator motor assembly, a new power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are installed.

  33. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door window regulator assembly.
    2. Temporary install the temporary bolt to the rear door window regulator assembly.
    3. Temporarily install the rear door window regulator assembly with the 5 bolts.
      GTY430552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporary Bolt
    4. Tighten the temporary bolt and 5 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) 

  34. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. Connect the cable to the negative (-) auxiliary battery terminal.
    2. Connect the rear 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 rear power window regulator switch assembly.
    4. Disconnect the cable from the negative (-) auxiliary battery terminal.
    5. Insert the rear door glass sub-assembly into the rear door panel as shown in the illustration.
      GTY450526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the rear door glass sub-assembly with the 2 bolts.

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

      GTY424390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the grommet.
      GTY450528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Install the 2 bolts.
      GTY427355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      Screw

      Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 

    2. Install the rear door lower window division bar sub-assembly with the nut and screw.

      Nut 

      Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 

      Screw 

      Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) 

  36. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
      GTY424385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL REAR DOOR WEATHERSTRIP 
    1. Engage the 20 clips to install the rear door weatherstrip.
      GTY424386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door check assembly.
    2. Clean the bolt hole on the vehicle body.
    3. Clean the bolt threads of the bolt.
    4. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the rear door check assembly with the 2 nuts and bolt.
      GTY454785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Bolt 

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

      Nut 

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

  39. INSTALL REAR DOOR PANEL PROTECTOR 
    1. Engage the 2 guides, claw and clip to install the rear door panel protector.
      GTY450527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. 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.
      GTY448344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point
    3. Install the new 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 2 connectors.
  41. INSTALL REAR CURTAIN SUB-ASSEMBLY (w/ Rear Door Sunshade) 
    1. Engage the 3 guides.
      GTY424378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear curtain sub-assembly with the 7 screws.
  42. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 7 claws to install the rear door inner glass weatherstrip as shown in the illustration.
      GTY424397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  44. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.
      GTY450531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.
      GTY426928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly
    2. w/ Illumination:
      1. Connect the connector.
    3. Engage the claw and 9 clips to install the rear door trim board sub-assembly.
      GTY424394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 3 screws.
      GTY450529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the claw to close the cover.
      GTY424393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL REAR DOOR REAR GUIDE SEAL 
    1. Engage the 3 clips and claw to install the rear door rear guide seal.
      GTY424410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL 
    1. Connect the connector.
    2. Engage the 2 guides, 2 claws and 2 clips to install the rear power window regulator switch assembly with rear door upper armrest base panel.
      GTY424408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws to install the rear door inside handle bezel plug.
      GTY424401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [02/2014 - 11/2016]

  50. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 71

  51. INSTALL DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 72

  52. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Models with Jam Protection Function on 4 Windows) 

    Refer to INITIALIZATION [02/2014 - ]

  53. INSPECT POWER WINDOW OPERATION 
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