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Home >> Toyota >> 2017 >> Avalon XLE Plus >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (Except Hybrid) >> Rear Door >> Reassembly [10/2014 - ] >> Procedure

Reassembly [10/2014 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work (Refer to PRECAUTION [10/2014 - ] ).

  2. REPAIR INSTRUCTION 

    Refer to PROCEDURE - Step 2

  3. INSTALL NO. 2 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 3

  4. INSTALL NO. 3 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 4

  5. INSTALL NO. 1 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 5

  6. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 1

  7. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 2

  8. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  9. INSTALL REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 2

  10. INSTALL REAR DOOR NO. 3 WEATHERSTRIP 
    1. Clean the rear door panel.
    2. Engage the clip to install a new rear door No. 3 weatherstrip.
      GTY564834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Double-sided Tape
  11. INSTALL REAR DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 5 clips to install the rear door No. 2 weatherstrip.
      GTY582694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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.
      GTY597607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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) 

  13. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the rear door rear outside handle pad.
      GTY360901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the rear door front outside handle pad.
      GTY360904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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.
      GTY360899Courtesy 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, and slide the rear door outside handle assembly toward the front of the vehicle to install it.
    3. Move the lever back as shown in the illustration to lock the door outside handle assembly.
      GTY360900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the claw to temporary install the rear door outside handle cover.
      GTY582701Courtesy 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) 

  17. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the rear door inside locking cable assembly.
      GTY360830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 claws.
      GTY360868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the rear door lock remote control cable assembly.
      GTY360833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw.
      GTY360863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY 
    NOTE:
    • When reusing the removed rear door lock with motor 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 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.
        GTY582700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert the rear door lock with motor assembly to the rear door outside handle release plate, and set it to the rear door panel.
      GTY568233Courtesy 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 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) 

  20. 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.
      GTY582690Courtesy 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.

  21. 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.
      GTY605655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 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) 

  22. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY 
    1. Engage the guide.
      GTY582692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new rear door inside panel reinforce sub-assembly with the 4 screws.
  23. INSTALL REAR DOOR FRAME GARNISH 
    1. Engage the clip to install a new rear door frame garnish.
      GTY552488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. Connect the cable to the negative (-) 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 cable from the negative (-) battery terminal.
    4. Disconnect the rear power window regulator switch assembly.
    5. Insert the rear door glass sub-assembly into the rear door panel along the front door glass run as indicated by the arrows, in the order shown in the illustration.
      GTY361312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the rear door glass sub-assembly with the 2 bolts.
      GTY582656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  25. INSTALL REAR DOOR REAR GUIDE SEAL 
    1. Install the rear door rear guide seal with the 2 screws as shown in the illustration.
      GTY360948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY 
    1. Install the rear door lower window frame sub-assembly with the 2 screws and 2 bolts.
      GTY544252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Screw
  27. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
      GTY582655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REAR DOOR WEATHERSTRIP 
    1. Engage the 19 clips to install the rear door weatherstrip.
      GTY582660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door check assembly.
    2. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Install the rear door check assembly with the 2 nuts and bolt.
      GTY580507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Nut

      Bolt 

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Nut 

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

  30. 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.
      GTY550711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 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. Connect the connector.
  31. INSTALL REAR DOOR TRIM BRACKET 
    1. Install the rear door trim bracket with the 2 screws.
      GTY582646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL REAR REFLEX REFLECTOR ASSEMBLY 
    1. for LH Side:
      1. Engage the 2 claws to install the rear reflex reflector assembly.
        GTY582648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for RH Side:
      1. Engage the 2 claws to install the rear reflex reflector assembly.
        GTY582645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR NO. 2 SPEAKER ASSEMBLY WITH BRACKET 

    Refer to PROCEDURE - Step 2

  34. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 3 claws to install the rear door inner glass weatherstrip.
      GTY363480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. 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.
      GTY582650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Install the No. 1 door scuff plate clamp.
      GTY582649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each connector and install the rear door trim board sub-assembly.
    3. Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.
      GTY593325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly
    4. Engage the rear door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.
      GTY372429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Reference Boss
    5. Engage the 7 clips and install the rear door trim board sub-assembly.
      GTY552484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 3 screws.
      GTY552485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If protective tape has been applied, remove it.

  37. INSTALL NO. 1 REAR DOOR STIFFENER CUSHION 
    1. Install the No. 1 rear door stiffener cushion with the screw.
      GTY469614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL 
    1. Connect each connector.
    2. w/ illumination:
      1. Engage the 2 clamps.
        GTY582324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the guide and 2 clips.
      GTY376951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 2 guides, clip and 7 claws to install the rear power window regulator switch assembly with rear door armrest base panel.
      GTY376954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If protective tape has been applied, remove it.

  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws to install the rear door inside handle bezel plug.
      GTY380013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  41. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    (Refer to INITIALIZATION [10/2014 - ] )

  42. INSPECT POWER WINDOW OPERATION 

    (Refer to OPERATION CHECK [10/2014 - ] )

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