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Home >> Toyota >> 2021 >> Avalon TRD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (2 Of 2) >> Rear Door >> Reassembly [08/2020 -] >> Procedure

Reassembly [08/2020 -]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch (for Gasoline Model) or power switch (for HV Model) 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 [04/2018 -]

  2. INSTALL REAR DOOR SILENCER PAD 
    1. Clean the rear door panel surface.
      1. Remove any remaining butyl tape from the rear door panel.
      2. Wipe off any tape adhesive residue with cleaner.
    2. Remove the release paper from a new rear door silencer pad.

      HINT: 

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

    3. Install the rear door silencer pad as shown in the illustration.
      GTY944529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      INSTALLATION POSITION

      Area Measurement
      a 20.3 mm (0.799 in.)
      b 32.9 mm (1.30 in.)
      c 15°
  3. INSTALL REAR DOOR NO. 3 WEATHERSTRIP 
    1. Clean the rear door panel.
    2. Remove the release paper from a new rear door No. 3 weatherstrip.

      HINT: 

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

    3. Install the rear door No. 3 weatherstrip.
      GTY859427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape - -
  4. REPAIR INSTRUCTION 

    Refer to PROCEDURE - Step 2

  5. INSTALL NO. 2 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 3

  6. INSTALL NO. 3 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 4

  7. INSTALL NO. 1 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 5

  8. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 1

  9. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 2

  10. INSTALL REAR DOOR FRONT OUTSIDE SEAL 
    1. Engage the guide to install the rear door front outside seal.
      GTY932913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE) 

    Refer to PROCEDURE - Step 3

  12. INSTALL DOOR WINDOW FRAME MOULDING CLIP 
    1. Engage the 2 claws to install the door window frame moulding clip.
      GTY868760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 2

  14. INSTALL REAR DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 5 clips to install the rear door No. 2 weatherstrip.
      GTY868757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL REAR DOOR PANEL CUSHION 
    1. Engage the 4 claws to install 2 new rear door panel cushions.
      GTY868756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER (w/ Cover) 
    1. Engage the 4 claws to install the rear door lock child protection cover.
      GTY868755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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 guide and claw as shown in the illustration.
      GTY849508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    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) 

      GTY868751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 3 guides and claw to install the rear door rear outside handle pad.
      GTY868753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the guide and 2 claws to install the rear door front outside handle pad.
      GTY932911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the claw.
      GTY932910Courtesy 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) 

  21. 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.
      GTY900091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    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.
    3. Move the lever as shown in the illustration and engage the 2 claws to secure the rear door outside handle assembly.
      GTY895461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engage in this Direction
  22. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  23. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door window regulator assembly.
    2. Temporarily install the temporary bolt to the rear door window regulator assembly.
    3. Temporarily install the rear door window regulator assembly with the 5 bolts.
      Fig 1: Identifying Rear Door Window Regulator Assembly Bolts With Tightening Sequence
      GTY869770Courtesy 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) 

    5. Connect the connector.
    6. Engage the 2 claws to install the rear door No. 3 service hole cover.
      GTY868658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. Connect the rear power window regulator switch assembly.
    2. for Gasoline Model:
      1. Connect the cable to the negative (-) battery terminal.
    3. for HV Model:
      1. Connect the cable to the negative (-) auxiliary battery terminal.
    4. for Gasoline Model:
      1. Turn the engine switch on (IG).
    5. for HV Model:
      1. Turn the power switch on (IG).
    6. Move the rear door window regulator assembly so that the door glass bolt holes can be seen.
    7. for Gasoline Model:
      1. Turn the engine switch off.
    8. for HV Model:
      1. Turn the power switch off.
    9. for Gasoline Model:
      1. Disconnect the cable from the negative (-) battery terminal.
    10. for HV Model:
      1. Disconnect the cable from the negative (-) auxiliary battery terminal.
    11. Disconnect the rear power window regulator switch assembly.
    12. Insert the rear door glass sub-assembly into the rear door panel as shown in the illustration.
      NOTE:

      Do not damage the rear door glass sub-assembly.

      GTY855702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
    13. Install the rear door glass sub-assembly with the 2 bolts.
      GTY868669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    14. Install the hole plug.
      GTY868667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REAR DOOR REAR GUIDE SEAL 
    1. Temporarily install the rear door rear guide seal as shown in the illustration.
      GTY944564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the rear door rear guide seal with the 2 screws.
      GTY868643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR DOOR WEATHERSTRIP 
    1. Clean the rear door panel.
    2. Remove the release paper from a new rear door weatherstrip.

      HINT: 

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

    3. Engage the 21 clips and install the rear door weatherstrip.
      GTY889461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
    4. Engage the clip.
      GTY868648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Clean the bolt hole in the vehicle body.
    2. Clean the threads of the bolt.
    3. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the rear door check assembly with the 2 nuts and bolt.
      GTY936180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt

      Bolt 

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

      Nut 

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

  28. INSTALL REAR DOOR FRAME GARNISH 
    1. Engage the 2 claws to install the rear door frame garnish.
      GTY868641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY 
    1. Install the 2 bolts.
      GTY868647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear door rear lower window frame sub-assembly with the 2 screws.
      GTY868650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
      GTY868649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL HOLE PLUG 
    1. Install the hole plug.
      GTY868645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL REAR DOOR NO. 2 SERVICE HOLE COVER 
    1. Install the rear door No. 2 service hole cover as shown in the illustration.
      GTY933360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the clip to connect the rear door weatherstrip as shown in the illustration.
      GTY868615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 2 guides and install the rear door inner glass weatherstrip as shown in the illustration.
      GTY921427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
  34. INSTALL REAR DOOR SERVICE HOLE COVER 
    1. Engage the 9 clips to install the rear door service hole cover.
      GTY868610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 clamps.
      GTY868608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
  35. INSTALL REAR DOOR NO. 1 TRIM BRACKET 
    1. Install the rear door No. 1 trim bracket with the screw.
      GTY868617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  37. INSTALL REAR DOOR ORNAMENT 
    1. Engage the 2 guides to install the rear door ornament as shown in the illustration.
      GTY937557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  38. INSTALL REAR DOOR PULL HANDLE 
    1. Engage the guide and 4 claws as shown in the illustration.
      GTY878217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the rear door pull handle with the 2 screws.
  39. INSTALL REAR DOOR TRIM COVER 
    1. Engage the 2 guides to install the rear door trim cover as shown in the illustration.
      GTY869334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the guide as shown in the illustration.
      GTY927379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    3. Install the rear armrest assembly with rear door trim cover with the 9 screws.
      GTY867649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL REAR DOOR TRIM BODY BRACKET 
    1. Install the rear door trim body bracket with the 3 screws.
      GTY867647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL REAR DOOR SPEAKER GRILLE SUB-ASSEMBLY 
    1. Engage the 2 guides as shown in the illustration.
      GTY939002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the rear door speaker grille sub-assembly with the 2 screws.
  42. INSTALL REAR NO. 2 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  43. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 3 claws to install the rear door inside handle sub-assembly.
      GTY868502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the connector.
      GTY868501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the rear door lock open lever remote control cable and rear door inside lock/unlock knob locking cable to the rear door inside handle sub-assembly as shown in the illustration.
      GTY860822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Door Inside Lock/Unlock Knob Locking Cable
      *2 Rear Door Lock Open Lever Remote Control Cable
      Install in this Direction
    3. Engage the guide, 8 clips and 6 claws as shown in the illustration.
      GTY851821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    4. Install the rear door trim board sub-assembly with the 3 screws.
      GTY868499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL 
    1. Connect the connector.
    2. Engage the 3 claws to install the rear power window regulator switch assembly with rear door upper armrest base panel as shown in the illustration.
      GTY917209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  46. INSTALL REAR DOOR TRIM ASSEMBLY COVER 
    1. Engage the 2 guides and claw to install the rear door trim assembly cover.
      GTY932852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL REAR DOOR ARMREST COVER SUB-ASSEMBLY 
    1. Engage the 3 claws to install the rear door armrest cover sub-assembly.
      GTY868492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    for A25A-FKS:

    Refer to PROCEDURE - Step 2

    for A25A-FXS:

    Refer to PROCEDURE - Step 2

    for 2GR-FKS:

    Refer to PROCEDURE - Step 2

  49. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for HV Model) 

    Refer to PROCEDURE - Step 3

  50. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    for Gasoline Model:

    Refer to INITIALIZATION [04/2018 -]

    for HV Model:

    Refer to INITIALIZATION [04/2018 -]

  51. INSPECT POWER WINDOW OPERATION 

    for Gasoline Model:

    Refer to OPERATION CHECK [04/2018 -]

    for HV Model:

    Refer to OPERATION CHECK [04/2018 -]

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