Rear Door: Overhaul

HINT:

• The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
• Use the same procedures on the RH side as on the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (see STANDARD BOLT ).

1. REMOVE POWER WINDOW REGULATOR SWITCH ASSY REAR 
   1. Using a screwdriver, remove the power window regulator switch assy rear, then disconnect the connector.

   HINT:

   Tape up the screwdriver tip before use.

   Fig 1: Removing Power Window Regulator Switch Assy Rear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH 
   1. Using a screwdriver, remove the rear door inside handle bezel plug.

   HINT:

   Tape up the screwdriver tip before use.

   Fig 2: Removing Rear Door Inside Handle Bezel Plug LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH 
   1. Remove the 2 screws.
   2. Using a screwdriver, remove the rear door trim board.

      HINT:

      Tape up the screwdriver tip before use.

   3. Remove the inside handle, then disconnect the 2 cables from the rear door lock assy.
      Fig 3: Removing Rear Door Trim Board Sub-Assy LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE REAR DOOR SERVICE HOLE COVER LH 
   1. Disconnect each connector and remove the rear door service hole cover.
   NOTE: Remove the remained tape on the body side.
5. REMOVE REAR DOOR WEATHERSTRIP LH 
   1. Using a screwdriver, remove the door weatherstrip.

   HINT:

   Tape up the screwdriver tip before use.

6. REMOVE DOOR WEATHERSTRIP LH CLIP 
   1. Using a roof moulding remover, remove the door weatherstrip clip.
7. REMOVE REAR DOOR WEATHERSTRIP NO.2 LH 
   1. Using a screwdriver, remove the rear door weatherstrip No.2.

   HINT:

   Tape up the screwdriver tip before use.

8. REMOVE REAR DOOR NO.3 WEATHERSTRIP LH 
9. REMOVE REAR DOOR BELT MOULDING ASSY LH (See  REAR DOOR BELT MOULDING ASSY LH  ) 
10. REMOVE REAR DOOR GLASS RUN LH 
11. REMOVE REAR DOOR WINDOW FRAME SUB-ASSY REAR LOWER LH 
    1. Remove the screw.
    2. Remove the 2 bolts and rear door window frame rear lower.
12. REMOVE REAR DOOR QUARTER WINDOW GLASS LH 
    1. Remove the rear door quarter window glass.
13. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP LH 
14. REMOVE REAR DOOR GLASS SUB-ASSY LH 

    HINT:

    Insert a shop rag inside the door panel so that the glass is not scratched.

    1. Open the door glass.
    2. Tilt the door glass and disconnect the roller of the regulator from the channel to remove the door glass.
    NOTE: Do not damage the door glass.

    HINT:

    Pull the glass upward to remove it.

15. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Disconnect the connector.
    2. Loosen the temporarily installed bolt.
       NOTE: When the temporarily installed bolt is removed, the rear door window regulator might drop and be deformed.
    3. Remove the 3 bolts and rear door window regulator.
16. REMOVE POWER WINDOW REGULATOR MOTOR ASSY RH 
    1. Using a torx wrench (T25), remove the 3 torx screws and the power window regulator motor assy.
17. REMOVE REAR DOOR W/MOTOR LOCK ASSY LH 
    1. Disconnect the connector.
    2. Using a torx wrench (T30), remove the 3 torx screws and the rear door with motor lock assy.
18. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH 
    1. Using a torx wrench (T30), loosen the torx screw and remove the rear door outside handle cover.
19. REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH 
    1. Pull and hold the release plate of the outside handle frame, as shown in Fig 4.
       Fig 4: Pulling And Holding Release Plate Of Outside Handle Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pushing the outside handle in the arrow mark direction in Fig 5, remove the rear door outside handle.
    NOTE: If the release plate is not pulled and held when removing the outside handle assy, then the release plate will interfere with the outside handle and it will damage the release plate.
    Fig 5: Removing Rear Door Outside Handle

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a torx wrench (T30), loosen the torx screw and remove the rear door outside handle frame.
21. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a torx wrench (T30), install the rear door outside handle frame with the torx screw.

       Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf) 

22. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH 
    1. Using a torx wrench (T30), install the rear door outside handle cover with the torx screw.

       Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf) 

23. INSTALL REAR DOOR W/MOTOR LOCK ASSY LH 
    1. Install a new door lock wire harness packing.
       NOTE:

       • If reusing a door lock that has been removed, replace the packing in the connecting part with a new packing.
       • Be careful that no grease and dirt sticks to the packing surface in the connecting part.
       • Reusing removed packing or using damaged packing will allow water to penetrate through the connecting part, resulting in a malfunction of the door lock.
    2. Engage the lock assy with rear 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 assy.
    3. Using a torx wrench (T30), install the rear door lock assy with the 3 torx screws and bolt.

       Torque: 5.0 N.m (51 kgf.cm, 44 in. lbf) 

24. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Apply MP grease to the sliding and rotating parts of the regulator assy.
    2. Using a torx wrench (T25), install the 3 torx screws and the power window regulator motor assy.

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

    3. If the jam protection does not function properly, perform the following procedure.

    HINT:

    It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed.

    1. Remove the power window motor.

       HINT:

       Place the matchmarks on the power window motor and window regulator gear.

    2. Connect the power window motor and power window switch to the wire harness of the vehicle.
    3. Turn the ignition switch ON and operate the power window switch to idle the power window motor in the upper direction for more than 6 rotations or less than 10 rotations (4 seconds or more).
    4. Assemble the power window motor and regulator.

       HINT:

       • The motor should be installed when the regulator arm is in the middle, not around the upper end (more than 50 mm clearance is necessary from the upper end).
       • Align the matchmarks on the power window motor and window regulator gear when installing the power window motor.
    5. Assemble the power window regulator and door glass.

    HINT:

    Never rotate the motor in the lower direction until the installation of the window glass is completed.

25. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Temporarily install the 3 bolts to the window regulator sub-assy.
    2. Using the pre-installed 3 bolts, temporarily install the window regulator sub-assy to the rear door panel.
    3. Tighten the 3 bolts and the temporarily installed bolt.

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

    4. Connect the connector.
26. INSTALL REAR DOOR GLASS SUB-ASSY LH 
    1. Install the rear door glass.
       1. Connect the power window switch to the wire harness and turn the ignition switch to the ON position.
       2. Repeat UP and DOWN operation several times manually.
       3. Check if AUTO UP/AUTO DOWN function operates in the automatic operation.

    HINT:

    • Note that the jam protection function does not operate just after resetting.
    • Reset the regulator again when performing the reverse operation after fully closing the window by AUTO UP operation.
27. INSPECT POWER WINDOW FUNCTION (See  ON-VEHICLE INSPECTION  ) 
28. INSTALL REAR DOOR NO.3 WEATHERSTRIP LH 
    1. Install a new rear door No.3 weatherstrip to the door panel.
29. INSTALL REAR DOOR WEATHERSTRIP NO.2 LH 
    1. Install a new rear door weatherstrip No.2 to the door panel.
30. INSTALL REAR DOOR SERVICE HOLE COVER LH 
    1. Install a new service hole cover to the door panel.

    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, sealing condition should be confirmed.
      Fig 6: Installing Service Hole Cover LH To Door Panel

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002