Rear Door: Service and Repair

REAR DOOR (for Double Cab)

Rear Door (for Double Cab):

Rear Door (for Double Cab):

Rear Door (for Double Cab):

Rear Door (for Double Cab):

DISASSEMBLY

1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH






a. Using a screwdriver, detach the 4 claws and remove the inside handle bezel.

HINT: Tape the screwdriver tip before use.

2. REMOVE REAR DOOR ARMREST UPPER BASE PANEL LH






a. Using a screwdriver, detach the 2 clips and rear door armrest upper base panel. Then disconnect the connector.

HINT: Tape the screwdriver tip before use.

3. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY






a. Detach the 4 claws and remove the power window regulator switch.

4. REMOVE REAR DOOR FRAME GARNISH LH






a. Detach the 4 clips and remove the rear door frame garnish.

5. REMOVE COURTESY LIGHT ASSEMBLY






a. Detach the claw and remove the courtesy light from the door trim.
b. Disconnect the connector.

6. REMOVE REAR DOOR ARMREST COVER LH
7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the 2 screws.






b. Using a clip remover, remove the clip.
c. Detach the 9 clips and remove the trim cover. Then disconnect the connector.
d. Disconnect the 2 cables from the inside handle.






8. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER LH
9. REMOVE REAR DOOR NO.2 TRIM BRACKET






a. Remove the 2 screws and bracket.

10. REMOVE REAR SPEAKER ASSEMBLY
11. REMOVE REAR DOOR SERVICE HOLE COVER LH






a. Disconnect the connector and 2 clamps.
b. Remove the rear door service hole cover.

HINT: Remove the remaining tape on the door.

12. REMOVE REAR DOOR GLASS RUN LH






a. Remove the rear door glass run.

13. REMOVE REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY LH






a. Remove the 4 bolts and rear door window rear lower frame.

HINT: Remove the frame through the service hole.

NOTICE: Be careful when removing the bolts as the frame may fall and become damaged.

14. REMOVE REAR DOOR REAR NO.2 GLASS RUN LH
a. Remove the rear door glass run from the rear door window rear lower frame.

15. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH






a. Remove the rear door glass from the rear door window regulator as shown in the illustration.

NOTICE: Do not damage the door glass.

16. REMOVE REAR DOOR WINDOW FRONT LOWER GUIDE SUB-ASSEMBLY LH






a. Remove the 2 bolts and rear door window front lower guide.

HINT: Remove the frame through the service hole.

NOTICE: Be careful when removing the bolts as the frame may fall and become damaged.

17. REMOVE REAR DOOR FRONT NO.2 GLASS RUN LH
a. Remove the rear door glass run from the window frame front lower.

18. REMOVE REAR DOOR GLASS WEATHERSTRIP OUTER
19. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH






a. Disconnect the connector.
b. Loosen the temporary bolt.

NOTICE: Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall, causing damage.

c. Remove the 3 bolts and window regulator.
d. Remove the window regulator through the service hole.
e. Remove the temporary bolt from the door window regulator.

20. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH






a. Using a T25 "TORX" driver, remove the 3 screws and motor.

NOTICE: Be careful when removing the screws as the motor may fall and become damaged.

21. REMOVE REAR DOOR LOCK ASSEMBLY LH






a. Disconnect the connector.
b. Using a T30 "TORX" wrench, remove the 3 screws and door lock.

HINT: Remove the door lock through the service hole.

NOTICE: Be careful when removing the bolts as the door lock may fall and become damaged.

22. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH






a. Remove the rear door lock remote control cable.

23. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH
a. Using a screwdriver, detach the 3 claws.






HINT: Tape the screwdriver tip before use.

b. Remove the rear door inside locking cable.






24. REMOVE REAR DOOR LOCK CHILD PROTECTION COVER LH
25. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH
a. Remove the 2 hole plugs.






b. Remove the 2 bolts and outside handle.






26. REMOVE REAR DOOR LOCK OPEN ROD LH
27. REMOVE REAR DOOR NO.2 WEATHERSTRIP LH






a. Using a clip remover, detach the 7 clips and remove the weatherstrip.

HINT: If clips are damaged during removal, replace them.

28. REMOVE REAR DOOR CHECK ASSEMBLY LH






a. Remove the bolt, 2 nuts and door check.

HINT: Remove the door check through the service hole.

NOTICE: Be careful when removing the bolts as the door check may fall and become damaged.

29. REMOVE REAR DOOR WEATHERSTRIP LH






a. Using a clip remover, detach the 34 clips and remove the weatherstrip.

HINT: If clips are damaged during removal, replace them.

REASSEMBLY

HINT:
- 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.

1. INSTALL REAR DOOR WEATHERSTRIP LH






a. Attach the 34 clips to install the weatherstrip.

HINT: If clips are damaged during installation, replace them.

2. INSTALL REAR DOOR CHECK ASSEMBLY LH






a. Apply MP grease to the sliding areas of the door check.
b. Install the door check to the door panel with the 2 nuts.

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

c. Apply adhesive to the threads of the bolt.

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

d. Install the bolt.

Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)

3. INSTALL REAR DOOR NO.2 WEATHERSTRIP LH






a. Attach the 7 clips to install the weatherstrip.

4. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH






a. Install the rear door outside handle with the 2 nuts.

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

b. Install the 2 hole plugs.

5. INSTALL REAR DOOR LOCK OPEN ROD LH
6. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH
7. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH
a. Install the rear door inside locking cable.






b. Attach the 3 claws.






8. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH






a. Install the rear door lock remote control cable.

9. INSTALL REAR DOOR MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the front door lock.
b. Install a new door lock wire harness packing to the door lock.

HINT:
- When reusing a door lock that has been removed, replace the packing in the connecting part with a new packing.
- Be careful that no grease or dirt sticks to the packing surface in the connecting part.
- Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.






c. Using a T30 "TORX" wrench, install the door lock with the 3 screws.

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

d. Connect the connector.

10. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the regulator motor.






b. Using a T25 "TORX" driver, install the motor with the 3 screws.

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

HINT: For a new front window regulator, the installation position of the regulator will be set when the self-tapping screws is are installed.

11. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Apply MP grease to the rear door power window regulator.
b. Loosely install the temporary bolt onto the window regulator.






c. Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.
d. Install the window regulator with the 3 bolts and tighten the temporary bolt.
e. Tighten the 4 bolts in the order shown in the illustration.

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

12. INSTALL REAR DOOR GLASS WEATHERSTRIP OUTER
13. INSTALL REAR DOOR FRONT NO.2 GLASS RUN LH
a. Install the rear door glass run to the rear door window front lower guide.

14. INSTALL REAR DOOR WINDOW FRONT LOWER GUIDE SUB-ASSEMBLY LH






a. Install the rear door window front lower guide to the door panel with the 2 bolts.

15. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH






a. Slide the rear door glass to install it as shown in the illustration.

NOTICE: Be careful not to damage the glass.

16. INSTALL REAR DOOR REAR NO.2 GLASS RUN LH
a. Install the rear door glass run to the rear door window rear lower frame.

17. INSTALL REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY LH






a. Install the rear door window rear lower frame LH to the door panel with the 4 bolts.

18. INSTALL REAR DOOR GLASS RUN LH






a. Install the rear door glass run.

19. INSTALL REAR DOOR SERVICE HOLE COVER LH






a. Attach the 2 clamps to install the rear door service hole cover.

NOTICE:
- When installing the service hole cover, pull out the links 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.

20. INSTALL REAR SPEAKER ASSEMBLY
21. INSTALL REAR DOOR TRIM NO.2 BRACKET






a. Install the bracket with the 2 screws.

22. INSTALL REAR DOOR GLASS WEATHERSTRIP INNER LH
23. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Connect the 2 cables to the inside handle.






b. Attach the inside handle's knob to the door trim board.
c. Attach the 9 clips to install the door trim board.






d. Install the inside handle and door trim board to the door trim panel with the screw.
e. Install the door trim board to the door panel with the screw
f. Attach the clip.

24. INSTALL REAR DOOR ARMREST COVER LH
25. INSTALL COURTESY LIGHT ASSEMBLY






a. Connect the connector.
b. Attach the claw to install the courtesy light.

26. INSTALL REAR DOOR FRAME GARNISH LH






a. Attach the 4 clips to install the rear door frame garnish.

27. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY






a. Attach the 4 claws to install the control switch.

28. INSTALL REAR DOOR ARMREST UPPER BASE PANEL LH






a. Connect the connector.
b. Attach the 2 clips to install the rear door armrest upper base panel.

29. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG LH






a. Attach the 4 claws to install the bezel plug.