Rear Door: Overhaul

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (see STANDARD BOLT SPECIFICATIONS ).

1. REMOVE REAR DOOR INSIDE HANDLE BEZEL 
   1. Using a screwdriver, disengage the 3 claws and remove the plug.

   HINT:

   Tape the screwdriver tip before use.

   Fig 1: Disengaging Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE DOOR PULL HANDLE 
   1. Remove the screw and pull handle.
   Fig 2: Removing Screw And Pull Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE REAR DOOR ARMREST BASE PANEL UPPER 
   1. Using a screwdriver, disengage the 2 clip and 4 claws, and remove the armrest base panel together with the 2 switches.

      HINT:

      Tape the screwdriver tip before use.

   2. Disconnect the switch connector.
   3. Using a screwdriver, disengage the 2 claws, remove the power window regulator switch.

   HINT:

   Tape the screwdriver tip before use.

   Fig 3: Disengaging Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE REAR DOOR TRIM BOARD SUB-ASSY 
   1. Remove the screw.
   2. Using a screwdriver, disengage the 7 clips and remove the trim board.

      HINT:

      • In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration.
      • If the clip cannot be reached with the clip remover, pull on the lower trim to remove it.
   Fig 4: Removing Screw

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSY 
   1. Using a screwdriver, disengage the claw labeled A as shown in the illustration.

      HINT:

      Tape the screwdriver tip before use.

   2. Move the inside handle in the direction indicated by the arrow mark in the illustration. The will release the claw and allow removal of the inside handle.
   3. Disconnect the 2 cables from the inside handle.
   Fig 5: Disconnecting 2 Cables From Inside Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE REAR SPEAKER ASSY 
   1. Using a drill of less than 4 mm (0.16 in.), drill out the heads of the 3 rivets and remove the speaker.
      NOTE:

      • Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
      • Be careful as the cut rivet will be hot.
   2. Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
   3. Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.
   Fig 6: Identifying Drill

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE REAR DOOR BELT MOULDING  
8. REMOVE REAR DOOR WINDOW MOULDING FRONT  
9. REMOVE DOOR FRAME GARNISH 
   1. Using a clip remover, disengage the claws and remove the garnish.
   Fig 7: Disengaging Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE REAR DOOR SERVICE HOLE COVER 
    1. Remove the 2 screws and bracket No. 2.
    2. Remove the service hole cover.
    NOTE: Remove the remaining tape on the door side.
    Fig 8: Removing Service Hole Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE REAR DOOR WINDOW GUIDE SUB-ASSY REAR 
    1. Remove the 3 screws labeled A, bolt and window guide rear together with the guide seal.
    2. Remove the screw labeled B and rear door guide seal.
    Fig 9: Removing Screws

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE REAR DOOR GLASS SUB-ASSY 

    HINT:

    Insert a shop rag inside the door panel to prevent the glass from being scratched.

    1. Connect the power window regulator switch.
    2. Move the inside handle in the direction indicated by the arrow mark in the illustration. The will release the claw and allow removal of the inside handle.
    3. Remove the 2 bolts and glass.
       NOTE: Be careful when removing the nuts as the glass may fall and become damaged.
    4. Disconnect the power window regulator switch.
    Fig 10: Removing 2 Bolts And Glass

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY 
    1. Disconnect the connector.
    2. Remove the 6 nuts and regulator.
    NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.

    HINT:

    Remove the window regulator through the service hole.

    Fig 11: Removing 6 Nuts And Regulator

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE POWER WINDOW REGULATOR MOTOR ASSY 
    1. Using a torx driver (T25), remove the 3 screws and motor.
    Fig 12: Removing Screws And Motor

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE REAR DOOR LOCK ASSY 
    1. Using a torx socket wrench (T30), remove the 3 screws and door lock.
    NOTE: Be careful when removing the bolts as the door lock may fall and become damaged.

    HINT:

    Remove the door lock through the service hole.

    Fig 13: Removing Screws And Door Lock

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE REAR DOOR OUTSIDE HANDLE COVER 
    1. Using a torx socket wrench (T30), loosen the screw and remove the outside handle cover.
    Fig 14: Identifying Torx Socket Wrench

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE REAR DOOR OUTSIDE HANDLE ASSY 
    1. Pull and hold the release plate of the outside handle frame, as shown in the illustration.
       Fig 15: Removing Rear Door Outside Handle Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pushing and pulling the outside handle in the arrow mark direction as shown in the illustration, remove the outside handle.
       NOTE: If the release plate is not pulled and held when removing the outside handle, the release plate will interfere with the outside handle and it will damage the release plate.
    3. Remove the outside handle pad front and rear.
    Fig 16: Removing Outside Handle Pad Front And Rear

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY 
    1. Using a torx socket wrench (T30), loosen the screw.
    2. Slide the outside handle frame and remove it.

       HINT:

       Remove the outside handle frame through the service hole.

    Fig 17: Removing Rear Door Outside Handle Frame

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE REAR DOOR CHECK ASSY 
    1. Remove the 2 nuts, bolt and the door check.

       HINT:

       Remove the door check through the service hole.

    Fig 18: Removing Nuts, Bolt

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the clip and remove the weatherstrip.

    HINT:

    If the clips are damaged, replace them with new clips.

21. INSTALL REAR DOOR CHECK ASSY 
    1. Apply MP grease to the sliding areas of the door check.
    2. Install the door check to the door panel with the 2 nuts.

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

    3. Apply adhesive to the bolt.

       Adhesive: 

       Part No. 08833-00070, THREE BOND 1324 or equivalent 

    4. Install the door check to the body panel with the bolt.

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

       HINT:

       Install the door check so that the rivet head is facing up.

    Fig 19: Installing Door

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY 
    1. Using a torx socket wrench (T30), install the handle frame with the screw.

       Torque: 7.0 N.m (56 kgf.cm, 49 in.lbf) 

    Fig 20: Installing Handle Frame With Screw

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL REAR DOOR OUTSIDE HANDLE ASSY 
    1. Install the outside handle pad front and rear.
    2. Pull and hold the release plate of the outside handle frame, as shown in the illustration.
       Fig 21: Installing Rear Door Outside Handle Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pushing the outside handle in the arrow marks direction as shown in the illustration, install the outside handle.
       NOTE: If the release plate is not pulled and held when installing the outside handle, the release plate will interfere with the outside handle and it will damage the release plate.
    Fig 22: Pushing Outside Handle

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Using a torx socket wrench (T30), install the outside handle cover with the screw.

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

    Fig 23: Identifying Torx Socket Wrench

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL REAR DOOR LOCK ASSY 
    1. Apply MP grease to the sliding and rotating areas of the door lock.
    2. Install a new door lock wire harness packing.
       NOTE:

       • If reusing the door lock that is removed, replace the packing in the connecting part with a new one.
       • Be careful that no grease or dirt will stick to the packing surface in the connecting part.
       • Reusing the packing that is removed or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock.
    3. Engage the lock with the door motor with the release plate of the outside handle, and then set it to the door panel.
       NOTE: Make sure that the release plate of the outside handle frame is securely engaged with the lock.
    4. Apply adhesive to the 3 screws.

       Adhesive: 

       Part No. 08833-00070, THREE BOND 1324 or equivalent 

    5. Using a torx socket wrench (T30), install the door lock with the 3 screws.

       Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf) 

    6. Connect the door lock connector.
    Fig 24: Installing Door Lock With 3 Screws

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL POWER WINDOW REGULATOR MOTOR ASSY 
    1. Using a torx driver (T25), install the motor with the 3 screws.

       Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

    Fig 25: Installing Motor With 3 Screws

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSY 
    1. Apply MP grease to the sliding and rotating areas of the window regulator.
       NOTE: Do not apply grease to the spring of the window regulator.
       Fig 26: Installing Rear Door Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosely screw bolt A onto the window regulator.
    3. Insert the window regulator into the door panel. Use bolt A to hang the window regulator on the door panel.
    4. Install the window regulator with the 5 bolts and tighten bolt A.

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

       NOTE: Be careful not to drop the window regulator as it may become damaged.
    5. Connect the window regulator connector.
    Fig 27: Loosing Screw Bolt A Onto Window Regulator

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL REAR DOOR GLASS SUB-ASSY 
    1. Install the glass run.
       NOTE: Be careful not to damage the glass.
    2. Install the door glass to the window regulator with the 2 bolts.

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

    Fig 28: Installing Door Glass To Window Regulator With 2 Bolts

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. INSTALL REAR DOOR WINDOW GUIDE SUB-ASSY REAR 
    1. Install the window guide rear together with the rear door guide seal.
    Fig 29: Installing Window Guide Rear Together With Rear Door Guide Seal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. INSTALL REAR DOOR SERVICE HOLE COVER 
    1. Apply butyl tape to the door as shown in the illustration.
    2. Install a new service hole cover.

       HINT:

       • When installing the service hole cover, pull out the links and connectors through the service hole cover.
       • There should be no wrinkles or folds after attaching the service hole cover.
       • After attaching the service hole cover, check the sealing quality.
    3. Install the trim bracket with the 2 screws.
    Fig 30: Installing Rear Door Service Hole Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. INSTALL FRONT NO.1 SPEAKER ASSY 
    1. Install the rear speaker to door.
    2. Using an air riveter or hand riveter, install the rear speaker.
       Fig 31: Installing Rear Speaker

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       • Do not prize the riveter. The riveter will be damaged and the mandrel will bend.
         Fig 32: Identifying Riveter

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • Do not tilt the riveter when fastening the rivet to the speaker as this will cause the rivet to be loose.
       • Do not have any space between the rivet head and the speaker. The rivet head must be completely flat against the speaker.
         Fig 33: Identifying Incorrect Position Of Riveter

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • Do not have any space between the speaker and door. Firmly hold together the two items while installing the rivet.
    3. Connect the speaker connector.
    Fig 34: Connecting Speaker Connector

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INITIALIZE POWER WINDOW SYSTEM (See  INITIALIZATION  )