RM38T0EC _59 Vehicle Exterior _113746 DOOR / HATCH _0510835 REAR DOOR A

DOOR / HATCH  REAR DOOR  REASSEMBLY  


CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)
B635761N01
0.917,4.75 2,4.917 1.083,0.167 1.594,5.281 1.927,5.281 false 2.25,5.271 2.583,5.271 false 1.917,3.781 2.25,3.781 false 1.26,3 1.594,3 false 0.656,1.958 0.917,1.958 false 1.865,1.396 2.031,1.396 2.031,1.396 2.198,1.146 false 1.896,0.74 2.104,0.74 false 4.969,2.094 5.302,2.094 false 5.667,3.188 5.917,2.688 5.917,2.688 6.083,2.688 false 1.677,0.281 1.938,0.281 false 0.354,1.698 0.5,1.417 0.5,1.417 0.667,1.417 false 2,4.833 2.167,4.833 2.167,4.833 2.385,5.104 false 3.198,5.531 3.531,5.531 false 2.646,5.156 3.198,5.51 0.552,0.354 18 false 10 6.125,2.542 6.677,2.896 0.552,0.354 18 false 9 0.979,2.875 1.531,3.229 0.552,0.354 18 false 8 1.604,1.271 2.156,1.625 0.552,0.354 18 false 7 5.729,2 6.281,2.354 0.552,0.354 18 false 6 1.385,1.844 1.938,2.198 0.552,0.354 18 false 5 1.688,0.573 2.24,0.927 0.552,0.354 18 false 4 1.375,5.167 1.927,5.521 0.552,0.354 18 false 3 5.594,2.042 5.75,2.24 0.156,0.198 10 false ● 0.813,2.917 0.969,3.115 0.156,0.198 10 false ● 1.24,1.865 1.396,2.063 0.156,0.198 10 false ● 1.479,1.302 1.635,1.5 0.156,0.198 10 false ● 1.531,0.615 1.688,0.813 0.156,0.198 10 false ● 3.229,5.552 3.542,5.75 0.313,0.198 10 false x3 3.615,5.406 4.167,5.76 0.552,0.354 18 false 2 1.708,3.667 2.26,4.021 0.552,0.354 18 false 1 1.521,0.198 1.677,0.396 0.156,0.198 10 false ● 2.052,0.208 2.365,0.406 0.313,0.198 10 false x5 0.448,1.635 0.76,1.833 0.313,0.198 10 false x3 0.76,1.323 0.917,1.521 0.156,0.198 10 false ● 1.021,4.76 3.469,4.917 2.448,0.156 8 false 5.0 (51, 44 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

1 DOOR WINDOW FRAME MOULDING CLIP 75792 - - -
2 REAR DOOR DUST PROOF SEAL 67837C - - -
3 REAR DOOR PANEL CUSHION 67003C - - -
4 REAR DOOR UPPER WINDOW FRAME MOULDING 75764A (Click here) - -
5 REAR DOOR WINDOW FRAME MOULDING(REAR PILLAR SIDE) 75766B (Click here) - -
6 REAR DOOR WINDOW FRAME MOULDING(CENTER PILLAR SIDE) 75762B (Click here) - -
7 REAR DOOR BELT MOULDING ASSEMBLY 75740 - - -
8 REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY 75076 (Click here) - -
9 REAR DOOR OUTSIDE LOWER MOULDING SUB-ASSEMBLY 75078 - - -
10 HOLE PLUG - - - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

B635760N01
0.198,2.438 1.281,2.604 1.083,0.167 2.917,2.917 4,3.083 1.083,0.167 1.26,4.417 2.344,4.583 1.083,0.167 3,2.25 4.083,2.417 1.083,0.167 5.177,1.052 5.51,1.052 false 4.302,0.896 4.635,0.896 false 5.552,0.583 5.885,0.583 false 3.688,0.323 4.021,0.323 false 3.042,2.667 3.375,2.667 false 3,3.802 3.448,3.802 false 1.448,1.198 1.615,1.198 1.615,1.198 1.677,1.719 false 0.75,2.438 0.75,2.104 false 2.917,3 2.75,3 2.75,3 2.583,2.5 true 2.354,4.5 2.688,4.5 false 2.75,2.583 2.833,2.333 2.833,2.333 3,2.333 true 2.708,3.677 3.125,4.031 0.417,0.354 18 false 17 3.969,0.781 4.385,1.135 0.417,0.354 18 false 12 3.615,2.51 4.031,2.865 0.417,0.354 18 false 11 4.031,0.188 4.448,0.542 0.417,0.354 18 false 14 5.583,0.917 6,1.271 0.417,0.354 18 false 13 1.115,1.104 1.531,1.458 0.417,0.354 18 false 16 5.938,0.438 6.354,0.792 0.417,0.354 18 false 15 0.833,2.042 1.25,2.396 0.417,0.354 10 false x3 2.854,4.438 3.115,4.646 0.26,0.208 10 false x4 0.281,2.448 1.521,2.729 1.24,0.281 8 false 5.5 (56, 49 in.*lbf) 3,2.938 4.229,3.188 1.229,0.25 8 false 4.0 (41, 35 in.*lbf) 1.354,4.427 2.813,4.729 1.458,0.302 8 false 8.0 (82, 71 in.*lbf) 3.073,2.271 4.302,2.521 1.229,0.25 8 false 4.0 (41, 35 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

11 REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 69204A (Click here) - -
12 REAR DOOR OUTSIDE HANDLE REAR PAD 69242G - - -
13 REAR DOOR OUTSIDE HANDLE FRONT PAD 69241G - - -
14 REAR DOOR OUTSIDE HANDLE COVER 69227L - - -
15 REAR DOOR OUTSIDE HANDLE ASSEMBLY 69240 - - -
16 REAR DOOR LOCK WITH MOTOR ASSEMBLY 69060A (Click here) - -
17 REAR DOOR WINDOW REGULATOR ASSEMBLY - (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque
V100135

MP Grease

B635759N01
2.667,5.167 3.75,5.333 1.083,0.167 1.729,0.667 1.927,0.313 1.927,0.313 2.094,0.313 false 0.51,0.729 0.51,0.396 false 1.479,1.417 1.813,1.417 false 2.948,1.458 2.948,1.125 false 0.844,2.333 1.177,2.333 false 2.292,4.083 2.625,4.083 false 4.198,4.5 4.531,4.5 false 5.917,4.375 6.25,4.375 false 2.792,2.99 2.938,3.521 2.938,3.521 3.104,3.521 false 5.125,0.458 5.458,0.458 false 3.75,5.25 3.917,5.25 3.917,5.25 3.938,5.583 false 2.813,1.479 3.167,1.833 0.354,0.354 18 false 25 2.677,3.927 3.26,4.302 0.583,0.375 18 false 27 2.198,0.177 2.74,0.531 0.542,0.354 18 false 26 1.26,2.198 1.615,2.552 0.354,0.354 18 false 20 4.615,4.375 4.969,4.729 0.354,0.354 18 false 21 3.104,3.375 3.458,3.729 0.354,0.354 18 false 18 4.781,0.333 5.135,0.688 0.354,0.354 18 false 22 0.375,0.75 0.729,1.104 0.354,0.354 18 false 24 6.323,4.25 6.677,4.604 0.354,0.354 18 false 23 4.063,5.542 4.396,5.729 0.333,0.188 10 false x2 1.875,1.292 2.229,1.646 0.354,0.354 18 false 19 2.75,5.177 4.167,5.438 1.417,0.26 8 false 8.5 (87, 75 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

18 REAR DOOR GLASS SUB-ASSEMBLY 68104 - - -
19 REAR DOOR QUARTER WINDOW WEATHERSTRIP 68189 - - -
20 REAR DOOR QUARTER WINDOW GLASS 68124B - - -
21 REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 67408H - - -
22 REAR DOOR GLASS RUN 68152C - - -
23 REAR DOOR FRAME GARNISH 67674A - - -
24 REAR DOOR REAR BELT SEAL 68199 - - -
25 REAR DOOR FRONT BELT SEAL 68197A - - -
26 REAR DOOR GLASS INNER WEATHERSTRIP 68174A - - -
27 REAR DOOR WEATHERSTRIP 67872 - - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque - -

B642745N01
5.833,1.417 6.833,1.583 1,0.167 6.146,3.302 6.896,3.469 0.75,0.167 0.365,4.083 1.448,4.25 1.083,0.167 6.521,0.24 6.854,0.24 false 6.823,1.531 6.906,1.531 6.906,1.531 6.969,2.406 false 5.354,3.792 5.792,3.792 false 3.458,5.375 3.667,5.375 false 0.813,2.573 0.958,2.573 false 2.542,2.292 2.875,2.292 false 1.823,1.281 2.031,1.281 false 6.573,0.583 6.906,0.583 false 4.927,4.875 5.26,4.875 false 6.417,1.833 6.583,1.833 6.583,1.833 6.615,2.333 false 6.531,3.083 6.531,3.302 false 6.542,0.969 6.823,0.969 false 0.448,3.698 0.448,3.198 0.448,3.198 0.615,3.198 false 0.833,3.583 0.917,3.917 0.917,3.917 0.917,4.083 false 6.167,0.094 6.646,0.479 0.479,0.385 18 false 35 6.104,1.698 6.552,2.094 0.448,0.396 18 false 28 6.906,2.479 7.156,2.698 0.25,0.219 10 false x2 3.156,5.188 3.594,5.542 0.438,0.354 18 false 30 5.667,4.24 5.917,4.458 0.25,0.219 10 false x3 5.021,3.656 5.458,4.01 0.438,0.354 18 false 29 0.667,3.073 1.115,3.417 0.448,0.344 18 false 34 0.5,2.448 0.938,2.802 0.438,0.354 18 false 32 2.208,2.167 2.698,2.531 0.49,0.365 18 false 31 1.5,1.125 1.979,1.469 0.479,0.344 18 false 33 5.802,0.427 7.021,0.823 1.219,0.396 18 false 38, 39 3.052,5.24 3.302,5.458 0.25,0.219 10 false ● 5.344,4.781 5.76,5.021 0.417,0.24 10 false ● *1 1.375,4.521 1.625,4.74 0.25,0.219 10 false x2 6.229,3.323 6.979,3.563 0.75,0.24 8 false 30 (306, 22) 5.875,1.427 6.875,1.677 1,0.25 8 false 5.5 (56, 49 in.*lbf) 6,3.313 6.156,3.51 0.156,0.198 10 false ★ 5.802,0.813 7.021,1.271 1.219,0.458 18 false 36, 37 0.448,4.094 1.646,4.344 1.198,0.25 8 false 4.0 (41, 35 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

28 REAR DOOR CHECK ASSEMBLY 68630 (Click here) - -
29 REAR SPEAKER ASSEMBLY 86160B (Click here) - -
30 REAR DOOR SERVICE HOLE COVER 67842E (Click here) - -
31 REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 69206C - - -
32 REAR DOOR TRIM BOARD SUB-ASSEMBLY 67604 (Click here) - -
33 REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL - - - -
34 REAR DOOR INSIDE HANDLE BEZEL PLUG 69284G - - -
35 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL - - - -
36 INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL - - - (Click here)
37 INITIALIZE POWER WINDOW CONTROL SYSTEM - - - (Click here)
38 INSPECT WINDOW CONTROL OPERATION - (Click here) - -
39 INSPECT POWER DOOR LOCK CONTROL SYSTEM - (Click here) - -

*1 BUTYL TAPE - -
V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part
V100135

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent ★ Precoated part

PROCEDURE

Hide 75792 1.INSTALL DOOR WINDOW FRAME MOULDING CLIP

Hide 67837C 2.INSTALL REAR DOOR DUST PROOF SEAL

Hide 67003C 3.INSTALL REAR DOOR PANEL CUSHION

Hide 75764A 4.INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

Z101186

Click here(Click here)

Hide 75766B 5.INSTALL REAR DOOR WINDOW FRAME MOULDING (REAR PILLAR SIDE)

Z101186

Click here(Click here)

Hide 75762B 6.INSTALL REAR DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

Z101186

Click here(Click here)

Hide 75740 7.INSTALL REAR DOOR BELT MOULDING ASSEMBLY

Hide 75076 8.INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY

Z101186

Click here(Click here)

Hide 75078 9.INSTALL REAR DOOR OUTSIDE LOWER MOULDING SUB-ASSEMBLY

Hide 10.INSTALL HOLE PLUG

Hide 69204A 11.INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

a.
B635684C01
2.813,0.063 3.094,0.417 0.281,0.354 18 false i 0.219,2 0.5,2.354 0.281,0.354 18 false ii 3.844,2.042 4.208,2.385 0.365,0.344 18 true iii
V100136

Screw
V100137

MP Grease
V113147

Install in this Direction - -


i.

Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly.


ii.

Engage the guide to install the rear door outside handle frame sub-assembly as shown in the illustration.


iii.

Using a T30 "TORX" socket wrench, tighten the screw

Torque:
4.0 N*m (41 kgf*cm, 35 in.*lbf)



Hide 69242G 12.INSTALL REAR DOOR OUTSIDE HANDLE REAR PAD

Hide 69241G 13.INSTALL REAR DOOR OUTSIDE HANDLE FRONT PAD

Hide 69227L 14.INSTALL REAR DOOR OUTSIDE HANDLE COVER

Torque:
4.0 N*m (41 kgf*cm, 35 in.*lbf)

Hide 69240 15.INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

Hide 69060A 16.INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

Z101186

Click here(Click here)

Hide 17.INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY

a.
B635683C01
0.604,0.125 0.885,0.479 0.281,0.354 18 false i 3.823,0.125 4.438,0.458 0.615,0.333 18 true ii, iii
V100135

Bolt
V100136

Connector
V100137

MP Grease - -


i.

Apply MP grease to the sliding parts of the rear door window regulator assembly.


ii.

Install the rear door window regulator assembly with the 4 bolts.

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


iii.

Connect the connector.



Hide 68104 18.INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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

Hide 68189 19.INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP

Hide 68124B 20.INSTALL REAR DOOR QUARTER WINDOW GLASS

Hide 67408E 21.INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

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

Hide 68152C 22.INSTALL REAR DOOR GLASS RUN

Hide 67674A 23.INSTALL REAR DOOR FRAME GARNISH

Hide 68199 24.INSTALL REAR DOOR REAR BELT SEAL

Hide 68197A 25.INSTALL REAR DOOR FRONT BELT SEAL

Hide 68174A 26.INSTALL REAR DOOR GLASS INNER WEATHERSTRIP

Hide 67872 27.INSTALL REAR DOOR WEATHERSTRIP

Hide 68630 28.INSTALL REAR DOOR CHECK ASSEMBLY

a.
B635688C01
0.427,0.083 1.698,1.719 1.271,1.635 1,0.24 1.76,0.615 0.76,0.375 18 false ii, iii 2.219,0.25 2.5,0.604 0.281,0.354 18 true i 4.083,0.125 4.417,0.469 0.333,0.344 18 true iv 5.094,0.531 5.469,0.771 0.375,0.24 10 true (A) 5.083,1.042 5.458,1.281 0.375,0.24 10 true (A) 6.396,0.75 6.771,0.99 0.375,0.24 10 true (B)
V100144

Cleaning Area
V100145

Adhesive


i.

Clean the bolt (B) hole in the vehicle body.


ii.

Clean the threads of the bolt (B).


iii.

Apply adhesive to the threads of the bolt (B).

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent



iv.

Install the rear door check assembly with the 2 bolts (A) and bolt (B).

Torque:
Bolt (A) : 5.5 N*m (56 kgf*cm, 49 in.*lbf)
Bolt (B) : 30 N*m (306 kgf*cm, 22 ft.*lbf)



Hide 86160B 29.INSTALL REAR SPEAKER ASSEMBLY

Z101186

Click here(Click here)

Hide 67842E 30.INSTALL REAR DOOR SERVICE HOLE COVER

a.
B642741C01
2.625,1.438 3.354,1.781 3.354,1.781 2.76,1.427 true 1.292,0.958 0.438,0.833 0.438,0.833 1.385,0.854 true 0.229,0.719 0.542,0.917 0.313,0.198 10 false *a 3.417,1.771 3.729,1.969 0.313,0.198 10 false *a 0.271,0.063 0.552,0.417 0.281,0.354 18 false i 3.844,0.083 4.125,0.438 0.281,0.354 18 false ii 1.573,3.125 2.271,3.51 0.698,0.385 18 true iii, iv 3.781,3.583 4.219,3.969 0.438,0.385 18 false v 2.771,2.854 3.021,3.073 0.25,0.219 10 true *a 4.823,3.052 5.073,3.271 0.25,0.219 10 true *a 4.469,5.167 4.719,5.385 0.25,0.219 10 true *a
*a Reference Point - -
V100143

Butyl Tape
V113147

Install in this Direction


i.

Apply new butyl tape to the rear door panel.

HINT:
·

Begin applying the butyl tape from the reference point shown in the illustration.

·

The butyl tape can be applied from either reference point.




ii.

Pass the rear door lock and unlock knob inside locking cable and open lever rear door lock remote control cable through a new rear door service hole cover.


iii.

Align the top of the rear door service hole cover with the reference point on the rear door panel and install it.


iv.

Align the bottom of the rear door service hole cover with the reference point on the rear door panel and install it.

NOTICE:
·

Securely install the rear door service hole cover LH to prevent wrinkles and air bubbles.

·

There should be no wrinkles or folds after installing the rear door service hole cover LH.

·

After installing the rear door service hole cover LH, check the seal quality.





Hide 69206C 31.INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

Hide 67604 32.INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

a.
B635771N01
2.24,0.094 2.521,0.448 0.281,0.354 18 false i 4.427,2 4.708,2.354 0.281,0.354 18 false ii 0.667,1.917 1.438,2.292 0.771,0.375 18 false iii, iv 2.823,2 2.979,2.198 0.156,0.198 10 true A

i.

Engage the guides to connect the open lever rear door lock remote control cable and rear door inside lock and unlock knob locking cable.


ii.

Engage the claws.


iii.

Engage the clips and guide to install the rear door trim board sub-assembly.


iv.

Install the 3 screws.

Torque:
Screw A : 4.0 N*m (41 kgf*cm, 35 in.*lbf)



Hide 33.INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL

Hide 69284G 34.INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

Hide 36. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART