RM38N0EC _59 Vehicle Exterior _111831 DOOR / HATCH _0501459 REAR DOOR A

DOOR / HATCH REAR DOOR REASSEMBLY

CAUTION / NOTICE / HINT

HINT:: ·

Use the same procedure for the RH side and LH side.

·

The following procedure is for the LH side.

PROCEDURE

Hide Display 1. PRECAUTION

NOTICE:: After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Hide Display 2. REPAIR INSTRUCTION

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Hide Display 67846A 3.INSTALL REAR DOOR FRONT OUTSIDE SEAL

Engage the guide to install a new rear door front outside seal.

Hide Display 75078 4.INSTALL REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY

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Hide Display 5.INSTALL HOLE PLUG

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

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Hide Display 75766A 7.INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

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Hide Display 75762B 8.INSTALL REAR DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

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Hide Display 75954A 9.INSTALL REAR INNER BLACK OUT TAPE

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE (for Rear Door)>INSTALLATION202111,999999,_59,_111849,_0500111,RM100000001Z1DP_01_0221,

Hide Display 75988E 10.INSTALL REAR DOOR OUTSIDE STRIPE

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Hide Display 75978H 11.INSTALL REAR DOOR LOWER OUTSIDE STRIPE

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE (for Rear Door)>INSTALLATION202111,999999,_59,_111849,_0500111,RM100000001Z1DP_01_0249,

Hide Display 67003C 12.INSTALL REAR DOOR PANEL CUSHION

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

Hide Display 67836D 13.INSTALL REAR DOOR LOCK CHILD PROTECTION COVER

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

Hide Display 75792 14.INSTALL DOOR WINDOW FRAME MOULDING CLIP

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

Hide Display 67874C 15.INSTALL REAR DOOR NO. 5 WEATHERSTRIP

Engage the 5 clips.

Engage the clip to install the rear door No. 5 weatherstrip.

Hide Display 67872 16.INSTALL REAR DOOR WEATHERSTRIP

Engage the 24 clips and install the rear door weatherstrip.

Hide Display 68630 17.INSTALL REAR DOOR CHECK ASSEMBLY

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

Clean the threads of the bolt (A).

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

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

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	Bolt (A)
	Bolt (B)

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

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

Hide Display 69204A 18.INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

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

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Install in this Direction

Engage the 2 guides as shown in the illustration.

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 19.INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

Engage the 4 guides to install the rear door rear outside handle pad.

Hide Display 69241G 20.INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

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

Hide Display 69227M 21.INSTALL REAR DOOR OUTSIDE HANDLE COVER

Engage the 2 claws.

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 22.INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

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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 as shown in the illustration.

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.

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

Hide Display 69060A 23.INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

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Hide Display 24.INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY

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

0.625,1.208 0.781,1.406 0.156,0.198 10 true 1 1.802,3.042 1.99,3.26 0.188,0.219 10 true 2 1.521,1.354 1.698,1.563 0.177,0.208 10 true 3 2.063,0.688 2.24,0.896 0.177,0.208 10 true 4 2.927,1.688 3.104,1.896 0.177,0.208 10 true 5 1.813,2.094 1.99,2.302 0.177,0.208 10 true 6

Temporarily install the rear door window regulator assembly with the 6 nuts.

Fully tighten the 6 nuts to install the rear door window regulator assembly.

HINT:: Tighten the nuts in the order shown in the illustration.

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

Connect the connector.

Hide Display 68104 25.INSTALL REAR DOOR GLASS SUB-ASSEMBLY

Connect the rear power window regulator switch assembly.

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

Turn the ignition switch to ON.

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

Turn the ignition switch off.

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

Disconnect the rear power window regulator switch assembly.

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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.

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

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

Hide Display 26.INSTALL HOLE PLUG

Install the hole plug.

Hide Display 68189 27.INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP

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

Hide Display 68124B 28.INSTALL REAR DOOR QUARTER WINDOW GLASS

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Install in this Direction

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

Hide Display 67408E 29.INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

Lift up the rear door weatherstrip as shown in the illustration.

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

Torque:: Bolt : 8.5 N*m (87 kgf*cm, 75 in.*lbf); Screw : 3.1 N*m (32 kgf*cm, 27 in.*lbf)

Install the rear door weatherstrip to the original position.

Hide Display 68152C 30.INSTALL REAR DOOR GLASS RUN

Install the rear door glass run.

Hide Display 75740 31.INSTALL REAR DOOR BELT MOULDING ASSEMBLY

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Hide Display 67674A 32.INSTALL REAR DOOR FRAME GARNISH

Engage the 3 claws to install the rear door frame garnish.

Hide Display 67842E 33.INSTALL REAR DOOR SERVICE HOLE COVER

Apply new butyl tape to the rear door panel.

0.333,0.344 0.521,0.521 true 2.958,0.51 3.115,0.365 true 2.729,3.115 2.729,2.948 true 0.135,0.229 0.333,0.438 0.198,0.208 10 true *a 3.125,0.26 3.323,0.469 0.198,0.208 10 true *a 2.656,3.125 2.854,3.333 0.198,0.208 10 true *a

*a	Reference Point

Pass the rear door lock remote control cable assembly and rear door inside locking cable assembly through a new rear door service hole cover.

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.

Engage the clamp.

Connect the connector.

Hide Display 86160B 34.INSTALL REAR SPEAKER ASSEMBLY

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Hide Display 68199 35.INSTALL REAR DOOR REAR BELT SEAL

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Install in this Direction

Install the rear door rear belt seal as shown in the illustration.

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

Hide Display 68197A 36.INSTALL REAR DOOR FRONT BELT SEAL

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Install in this Direction

Install the rear door front belt seal to the rear door inner glass weatherstrip as shown in the illustration.

Hide Display 68174A 37.INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

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Install in this Direction

Install the rear door inner glass weatherstrip with rear door front belt seal as shown in the illustration.

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

Hide Display 69206C 38.INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

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Install in this Direction

Engage the 3 claws to install the rear door inside handle sub-assembly as shown in the illustration.

Hide Display 39.INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL

Engage the 2 claws.

Install the rear power window regulator switch assembly with rear door armrest base panel with the 10 screws.

Hide Display 67604 40.INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

1.344,1.146 1.865,0.792 true 1.969,0.615 2.698,0.479 true 2.708,0.375 2.938,0.573 0.229,0.198 10 true *1 1.104,1.063 1.323,1.25 0.219,0.188 10 true *2

*1	Rear Door Inside Locking Cable Assembly
*2	Rear Door Lock Remote Control Cable Assembly
	Install in this Direction

Connect the connector.

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.