DOOR / HATCH REAR DOOR REASSEMBLY

Hide Display 1. PRECAUTION

NOTICE:: After turning the ignition 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.

Hide Display 67837C 2.INSTALL REAR DOOR DUST PROOF SEAL

a.

Engage the 2 claws to install 2 new rear door dust proof seals.

Hide Display 75792 3.INSTALL DOOR WINDOW FRAME MOULDING CLIP

a.

Engage the 2 claws to install the door window frame moulding clip.

Hide Display 67003C 4.INSTALL REAR DOOR PANEL CUSHION

a.

Engage the 2 claws to install a new rear door panel cushion.

Hide Display 75766A 5.INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>REAR DOOR WINDOW FRAME MOULDING>INSTALLATION201906,999999,_59,_080736,_0392557,RM100000001HRJ6_01_0177,

Hide Display 75764A 6.INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>REAR DOOR WINDOW FRAME MOULDING>INSTALLATION201906,999999,_59,_080736,_0392557,RM100000001HRJ6_01_0178,

Hide Display 75762B 7.INSTALL REAR DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>REAR DOOR WINDOW FRAME MOULDING>INSTALLATION201906,999999,_59,_080736,_0392557,RM100000001HRJ6_01_0170,

Hide Display 75740 8.INSTALL REAR DOOR BELT MOULDING

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>REAR DOOR BELT MOULDING>INSTALLATION202307,999999,_59,_080736,_0392554,RM100000002D3FH_01_0262,

Hide Display 67836D 9.INSTALL REAR DOOR LOCK CHILD PROTECTION COVER (w/ Cover)

a.

for Type A:

i.

Engage the 4 claws to install the rear door lock child protection cover.

b.

for Type B:

i.

Engage the 6 claws to install the rear door lock child protection cover.

Hide Display 69204A 10.INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

a.

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

b.

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Install in this Direction

Engage the guide and claw as shown in the illustration.

c.

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)

Hide Display 69242G 11.INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

a.

Engage the 3 guides and claw to install the rear door rear outside handle pad.

Hide Display 69241G 12.INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

a.

Engage the guide and 2 claws to install the rear door front outside handle pad.

Hide Display 69227L 13.INSTALL REAR DOOR OUTSIDE HANDLE COVER

a.

Engage the 2 claws.

b.

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)

Hide Display 69240 14.INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

a.

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Install in this Direction

Insert the front end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly.

b.

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.

c.

Move the lever as shown in the illustration and engage the 2 claws to secure the rear door outside handle assembly.

Hide Display 69060A 15.INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

Click hereVehicle Interior>DOOR LOCK>REAR DOOR LOCK>INSTALLATION202307,999999,_58,_080729,_0392012,RM100000002D3HD_01_0125,

Hide Display 16.INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY

a.

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

b.

Install the rear door window regulator assembly with the 6 nuts.

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

c.

Connect the connector.

Hide Display 68104 17.INSTALL REAR DOOR GLASS SUB-ASSEMBLY

a.

Connect the rear power window regulator switch assembly.

b.

Connect the cable to the negative (-) auxiliary battery terminal.

c.

Turn the ignition switch (for Gasoline Model) or power switch (for HV Model) on (IG).

d.

Move the rear door window regulator assembly so that the door glass bolt holes can be seen.

e.

Turn the ignition switch (for Gasoline Model) or power switch (for HV Model) off.

f.

Disconnect the cable from the negative (-) auxiliary battery terminal.

g.

Disconnect the rear power window regulator switch assembly.

h.

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Install in this Direction

Insert the rear door glass sub-assembly into the rear door panel as shown in the illustration.

NOTICE:: Do not damage the rear door glass sub-assembly.

i.

Install the rear door glass sub-assembly with the 2 bolts.

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

Hide Display 68189 18.INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP

a.

Install the rear door quarter window weatherstrip from the rear door quarter window glass.

b.

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Install the rear door quarter window weatherstrip with rear door quarter window glass as shown in the illustration.

Hide Display 67408H 19.INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

a.

Install the screw.

b.

Install the rear door window division bar sub-assembly with the 2 bolts.

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

Hide Display 67872 20.INSTALL REAR DOOR WEATHERSTRIP

a.

Clean the rear door panel.

i.

Remove any remaining double-sided tape from the rear door panel.

ii.

Wipe off any tape adhesive residue with cleaner.

b.

Remove the release paper from a new rear door weatherstrip.

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

c.

for COROLLA, LEVIN:

i.

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Double-sided Tape

Engage the 22 clips and install the rear door weatherstrip.

d.

for ALLION, LEVIN GT:

i.

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Double-sided Tape

Engage the 23 clips and install the rear door weatherstrip.

Hide Display 67844A 21.INSTALL REAR DOOR NO. 2 SERVICE HOLE COVER

a.

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Install in this Direction

Install the rear door No. 2 service hole cover as shown in the illustration.

b.

Engage the clip to connect the rear door weatherstrip as shown in the illustration.

Hide Display 68630 22.INSTALL REAR DOOR CHECK ASSEMBLY

a.

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

b.

Clean the threads of the bolt (B).

c.

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

Adhesive:: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

d.

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	Bolt (A)
	Bolt (B)

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 Display 68152C 23.INSTALL REAR DOOR GLASS RUN

a.

Install the rear door glass run.

Hide Display 67842E 24.INSTALL REAR DOOR SERVICE HOLE COVER

a.

Apply new butyl tape to the rear door panel.

b.

for COROLLA, LEVIN:

i.

0.417,0.49 0.635,0.49 false 2.844,0.563 3.042,0.563 false 1,3.146 1,2.927 false 0.25,0.385 0.563,0.542 0.313,0.156 10 false *a 3.073,0.458 3.385,0.615 0.313,0.156 10 false *a 0.927,3.156 1.24,3.313 0.313,0.156 10 false *a

*a	Reference Point

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

ii.

Attach the rear door service hole cover according to the reference points on the rear door panel.

NOTICE:: Securely install the rear door service hole cover preventing wrinkles and air bubbles.

c.

for ALLION, LEVIN GT:

i.

0.479,0.323 0.719,0.51 false 2.76,0.417 2.979,0.417 false 1.01,2.906 1.01,3.125 false 0.323,0.24 0.583,0.458 0.26,0.219 10 false *a 3,0.323 3.26,0.542 0.26,0.219 10 false *a 0.958,3.135 1.219,3.354 0.26,0.219 10 false *a

*a	Reference Point

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

ii.

Attach the rear door service hole cover according to the reference points on the rear door panel.

NOTICE:: Securely install the rear door service hole cover preventing wrinkles and air bubbles.

Hide Display 67858A 25.INSTALL REAR DOOR PANEL PROTECTOR

a.

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Install in this Direction

Install the rear door panel protector as shown in the illustration.

Hide Display 67848A 26.INSTALL REAR DOOR NO. 1 VENT SEAL

a.

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Install in this Direction

Engage the 2 guides and install the rear door No. 1 vent seal to the rear door inner glass weatherstrip as shown in the illustration.

b.

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Install the rear door inner glass weatherstrip with the rear door No. 1 vent seal as shown in the illustration.

Hide Display 67674A 27.INSTALL REAR DOOR FRAME GARNISH

a.

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Install in this Direction

Engage the 2 guides as shown in the illustration.

b.

Engage the clip to install the rear door frame garnish.

Hide Display 86160B 28.INSTALL REAR SPEAKER ASSEMBLY

Click hereAudio / Visual / Telematics>AUDIO / VIDEO>REAR DOOR SPEAKER>INSTALLATION202304,999999,_56,_080751,_0392318,RM100000002BLTT_01_0039,

Hide Display 69206C 29.INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

a.

Engage the 3 claws to install the rear door inside handle sub-assembly.

Hide Display 67604 30.INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

a.

2.344,0.917 2.781,0.625 true 2.771,1.75 2.365,1.354 true 2.802,0.531 3.01,0.698 0.208,0.167 10 true *1 2.802,1.656 3.01,1.844 0.208,0.188 10 true *2

*1	Rear Door Inside Lock/Unlock Knob Locking Cable
*2	Rear Door Lock Open Lever Remote Control Cable
	Install in this Direction

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.

b.

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Install in this Direction

Engage the guide, 6 claws and 8 clips as shown in the illustration.

c.

Install the rear door trim board sub-assembly with the 3 screws.

Hide Display 31.INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL

a.

Connect each connector.

b.

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Install in this Direction

Engage the 8 guides, 9 claws and 2 clips to install the rear power window regulator switch assembly with rear door upper armrest base panel as shown in the illustration.

Hide Display 69284G 32.INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

a.