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Home >> Toyota >> 2021 >> Prius Prime LE >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (1 Of 2) >> Rear Door >> Reassembly [09/2016 - 05/2019] >> Procedure

Reassembly [09/2016 - 05/2019]: Procedure

  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 [09/2016 - 01/2018] , or refer to PRECAUTION [01/2018 - 05/2019]

  2. REPAIR INSTRUCTION (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 1

  3. INSTALL REAR DOOR UPPER OUTSIDE STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 2

  4. INSTALL REAR DOOR OUTSIDE STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 3

  5. INSTALL REAR DOOR LOWER OUTSIDE STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 4

  6. INSTALL REAR DOOR REAR WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 1

  7. INSTALL REAR DOOR UPPER WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 2

  8. INSTALL REAR DOOR FRONT WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 3

  9. INSTALL REAR DOOR BELT MOLDING ASSEMBLY 

    Refer to PROCEDURE - Step 1

  10. 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. Engage the claw and install the rear door No. 3 weatherstrip.
      GTY596023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  11. INSTALL REAR DOOR DUST PROOF SEAL 
    1. Engage the 3 claws to install 3 new rear door dust proof seals.
      GTY609628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR DOOR PANEL CUSHION 
    1. Engage the 2 claws to install a new rear door panel cushion.
      GTY592730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 as shown in the illustration.
      GTY568434Courtesy 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) 

  14. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 3 guides and claw to install the rear door rear outside handle pad.
      GTY592734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the rear door front outside handle pad.
      GTY592736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the claw.
      GTY592737Courtesy 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 OUTSIDE HANDLE ASSEMBLY 
    1. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly.
      GTY541805Courtesy 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.
      GTY592747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  19. 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 3 bolts.
      Fig 1: Rear Door Window Regulator Assembly Tightening Sequence
      GTY594397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporary Bolt
    4. Tighten the temporary bolt and 3 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.
  20. INSTALL REAR DOOR GLASS CHANNEL FILLER 
    1. Apply soapy water to a new rear door glass channel filler.
    2. Install the rear door glass channel filler to the rear door glass sub-assembly at position shown in the illustration.
      GTY584071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Front Side
      *B Rear Side
      *a Edge of curved surface
      STANDARD DIMENSION

      Area Measurement
      A 5.0 mm (0.197 in.)
      B 5.0 mm (0.197 in.)
  21. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY 
    1. Apply soapy water to the channel filler side of the rear door glass channel sub-assembly.
    2. Using a plastic hammer, install the rear door glass channel sub-assembly to the position shown in the illustration.
      GTY591799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Front Side
      *B Rear Side
      *a Edge of curved surface
      STANDARD DIMENSION

      Area Measurement
      A 5.0 mm (0.197 in.)
      B 5.0 mm (0.197 in.)
      NOTE:

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

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. 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.

      GTY546829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
    2. Slide the rear door glass sub-assembly to install it as shown in the illustration.
      GTY592753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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 with rear door quarter window weatherstrip as shown in the illustration.
      GTY572464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  24. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Install the rear door window division bar sub-assembly with the screw and 2 bolts.
      GTY595557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Screw
      Bolt

      Screw 

      Torque: 3.1 N*m (32 kgf*cm, 27 in.*lbf) 

      Bolt 

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  25. 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 25 clips and install the rear door weatherstrip.
      GTY553351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Double-sided Tape
  26. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door check assembly.
    2. Clean the bolt hole in the vehicle body.
    3. Clean the threads of the bolt (B).
    4. Apply adhesive to the threads of the bolt (B).

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the rear door check assembly with the 3 bolts.
      GTY599283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Bolt (B) 

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

  27. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
      GTY592768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REAR DOOR NO. 2 SERVICE HOLE COVER 
    1. Install the rear door No. 2 service hole cover.
      GTY592769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REAR DOOR PANEL PROTECTOR 
    1. Install the rear door panel protector.
      GTY592771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 and rear door inside locking cable assembly through a new rear door service hole cover.
      GTY538882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.

  31. INSTALL REAR DOOR FRAME GARNISH 
    1. Engage the 2 claws to install the rear door frame garnish.
      GTY592571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  33. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 2 claws to install the rear door inside handle sub-assembly.
      GTY592577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL REAR DOOR NO. 2 VENT SEAL 
    1. Install the rear door No. 2 vent seal to the front door inner glass weatherstrip.
      GTY600326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  35. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP WITH REAR DOOR NO. 2 VENT SEAL 
    1. Install the rear door inner glass weatherstrip with rear door No. 2 vent seal as shown in the illustration.
      GTY541790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Install the No. 1 door scuff plate clamp as shown in the illustration.
      GTY547143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly to the rear door inside handle sub-assembly as shown in the illustration.
      GTY589953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly
      Install in this Direction
    3. Engage the 6 claws and guide.
      GTY1006817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 8 clips to install the rear door trim board sub-assembly.
    5. Install the 3 screws.
      GTY592585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL 
    1. Connect the connector.
    2. Engage the 2 clips and 2 claws to install the rear power window regulator switch assembly with rear door upper armrest base panel as shown in the illustration.
      GTY607765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  38. INSTALL REAR ARMREST ASSEMBLY 
    1. Engage the 3 clips and 7 claws to install the rear armrest assembly as shown in the illustration.
      GTY570199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  39. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws to install the rear door inside handle bezel plug.
      GTY592600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. 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 [09/2016 - 05/2019]

  41. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    Refer to INITIALIZATION [09/2016 - ]

  42. INSPECT POWER WINDOW OPERATION 

    Refer to OPERATION CHECK [09/2016 - 12/2018] , or refer to OPERATION CHECK [12/2018 - ]

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