Rear Door Installation

Apply MP grease to the sliding area of the rear door check.

When reusing a bolt labeled B:

1. Clean the threads of the bolt labeled B with non-residue solvent.
   

2. Apply adhesive to the threads of the bolt labeled B.
   

   Adhesive:

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
   

Install the rear door check with the 2 bolts labeled A and the bolt labeled 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}

Clean the rear door panel surface.

1. Using a heat light, heat the rear door panel surface.
   

2. Remove the double-sided tape from the rear door panel surface.
   

3. Wipe off any tape adhesive residue with cleaner.
   

Install a new rear door weatherstrip.

1. Remove the peeling paper from the face of the rear door weatherstrip.
   

   HINT:

   After removing the peeling paper, keep the exposed adhesive free from foreign matter.

2. Attach the 33 clips to install the rear door weatherstrip.
   

   HINT:

   Press the rear door weatherstrip firmly to install it.

3. Install the clip.
   

Install a new rear door panel cushion.

Attach the 2 claws to install the rear door rear outside handle pad.

Attach the 2 claws to install the rear door front outside handle pad.

Apply MP grease to the sliding area of the rear door outside handle frame.

Using a T30 "TORX" socket wrench, install the rear door outside handle frame with the screw.

Torque:

4.0 N*m{41 kgf*cm, 35 in.*lbf}

Install the rear door outside handle by moving it in the direction indicated by the arrow shown in the illustration.

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}

Install the rear door inside locking cable.

Attach the 3 claws to close the cover.

Install the rear door lock remote control cable.

Install a new door lock wiring harness seal to the rear door lock.

NOTICE:

1. When reusing the removed rear door lock, replace the door lock wiring harness seal on the connector with a new one.
   
2. Do not allow grease or dust to adhere to the surface of the connector which contacts the door lock wiring harness seal.
   
3. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may allow water into the connection. This may result in a malfunction of the rear door lock.
   

Apply MP grease to the sliding parts of the rear door lock.

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

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the rear door inside locking cable and rear door lock remote control cable to the clamps.

Connect the connector.

Install 5 new clips to the rear door outside moulding.

Attach the 5 clips to install the rear door outside moulding.

Install a nose piece to an air riveter or hand riveter.

Insert the mandrel part of a new rivet into the nose piece.

Using the riveter, install the 3 rivets as shown in the illustration.

HINT:

If the rivet cannot be cut, pull it once and cut it.

NOTICE:

1. Do not pry the rivet with the riveter as this will cause damage to the riveter and mandrel.
   

   Text in Illustration

   *1	Riveter
   *2	Mandrel
   *a	INCORRECT
   *b	CORRECT



2. Confirm that the rivets are seated properly against the rear door outside moulding.
   
3. Do not tilt the riveter when installing the rivet to the rear door outside moulding.
   
4. Do not leave any space between the rivet head and rear door outside moulding.
   

   Text in Illustration

   *1	Riveter
   *a	INCORRECT
   *b	CORRECT



5. Do not leave any space between the rear door outside moulding and rear door panel. Firmly hold together the 2 items while installing the rivet.
   

   Text in Illustration

   *1	Riveter
   *a	INCORRECT
   *b	CORRECT

Using a T25 "TORX" socket wrench, install the power window regulator motor with the 3 screws.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Apply MP grease to the sliding and rotating areas of the rear door window regulator.

Temporarily install the temporary bolt to the rear door window regulator.

Install the rear door window regulator with the 3 bolts, and then tighten the temporary bolt.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

NOTICE:

Be careful not to drop the rear door window regulator as it may become damaged.

Install the rear door glass channel filler to the rear door glass as shown in the illustration.

Standard:

Area	Dimension
A	2.7 mm (0.106 in.)

Apply soapy water to the inside of the rear door glass channel.

Using a plastic-faced hammer, tap the rear door glass channel onto the rear door glass to install the rear door glass channel as shown in the illustration.

Standard:

Area	Dimension
A	2.7 mm (0.106 in.)

Clean the vehicle body surface.

1. Using a heat light, heat the vehicle body surface.
   

2. Wipe off any tape adhesive residue with cleaner.
   

Installation temperature.

1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is higher than 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape to between 20 and 30°C (68 and 86°F) prior to installation.
   

   HINT:

   1. The most appropriate temperature for installing the tape is 25°C (77°F).
      
   2. When the temperature is low, the tape turns stiff and falls off easily. When the temperature is high, the tape loses elasticity.
      

Before installation.

1. Make sure any dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame) is removed, and that the surface is smooth. If the surface is rough or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.
   

   HINT:

   Spray water on the shop floor to settle any dust.

Key points for handling the tape.

1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and level.
   

   NOTICE:

   Do not bend the tape or leave it in a place with a high temperature.

Key points for the installation of the tape (how to use a squeegee and the installation procedure for a flat surface).

NOTICE:

1. Position the tape with a high level of accuracy to achieve a neat finish and to avoid peeling.
   
2. The tape cannot be reused because it deforms and will not fit after removal.
   

1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee 40 to 50° (for pressing forward) or 30 to 45° (for pulling) from the vehicle body surface and press with a force of 20 to 30 N (2 to 3 kgf) while moving the squeegee at a constant slow speed of 3 to 7 cm (1.2 to 2.8 in.) per second.
   
   

   
   
   
   

   NOTICE:

   Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles and air bubbles.

   HINT:

   1. Either angle of the squeegee (for pressing forward or for pulling) is acceptable.
      
   2. Be sure to apply the tape while removing the release paper 10 to 20 mm (0.393 to 0.787 in.) from the edge of the squeegee.
      
   
   

   Text in Illustration

   *A	Pressing	*B	Pulling
   *1	Squeegee	*2	Black Out Tape
   *3	Release Paper	-	-
   *a	Sectional View	*b	Non-padded Side
   *c	Padded Side	-	-

Key points for the installation of the tape (how to use a squeegee and the installation procedure for hemming surfaces).

1. If it is difficult to press the tape, press it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.
   

   HINT:

   When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

   Text in Illustration

   *1	Squeegee
   *a	First
   *b	Second
   *c	Third

Key points for the installation of the tape (how to use a squeegee and the installation procedure for corners).

1. Remove the release paper and apply the tape carefully with your fingers.
   

2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it to avoid wrinkles in the tape and achieve a neat finish.
   

Check after installation.

1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, apply new tape.
   

   NOTICE:

   Do not reuse the tape.

Align the perforations of the release paper of new No. 2 black out tape with line A and line B as shown in the illustration, and then apply the No. 2 black out tape.

Remove the release paper from the No. 2 black out tape.

Temporarily install the rear power window regulator switch assembly with rear door armrest base panel.

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

Operate the rear door window regulator so that the rear door glass can be installed.

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

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Toyota Fortuner RM000004W63000X.html).

Remove the rear power window regulator switch assembly with rear door armrest base panel.

Install the front side of the rear door glass run.

Apply MP grease to the sliding areas of the rear door glass channel as shown in the illustration.

Standard:

Area	Specified Condition
A	30 mm (1.18 in.)
B	155 mm (6.10 in.)

Install the rear door glass channel to the rear door window regulator as shown in the illustration.

NOTICE:

Do not damage the door glass.

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

Install the rear door quarter window glass.

Temporarily install the temporary bolt to the rear door window division bar.

Align the rear door glass run with the rear door window division bar.

Install the rear door window division bar with the bolt and screw, and then tighten the temporary bolt.

Finish installing the rear door glass run.

Apply new butyl tape to the rear door panel.

Pass the rear door inside locking cable, rear door lock remote control cable and wire harness through a new rear door service hole cover, and then attach the rear door service hole cover using the reference points on the rear door panel.

NOTICE:

1. Securely install the rear door service hole cover to prevent wrinkles and air bubbles.
   
2. There should be no wrinkles or folds after installing the rear door service hole cover.
   
3. After installing the rear door service hole cover, check the seal quality.
   

Install the rear door No. 2 trim bracket with the 2 screws.

Connect the rear door inside locking cable and rear door lock remote control cable to the rear door inside handle.

Attach the 2 guides as indicated by the arrow in the illustration, and then attach the claw to install the rear door inside handle.

Install a nose piece to an air riveter or hand riveter. Then insert the mandrel part of a new φ4 mm waterproof rivet into the nose piece.

Using an air riveter or hand riveter, install the speaker with 3 new rivets.

NOTICE:

1. Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
   

   Text in Illustration

   *1	Mandrel
   *2	Riveter
   *a	INCORRECT
   *b	CORRECT



2. Confirm that the rivets are seated properly against the speaker.
   

   Text in Illustration

   *1	Riveter
   *a	INCORRECT
   *b	CORRECT

3. Do not tilt the riveter when installing the rivet to the speaker.
   
4. Do not leave any space between the rivet head and speaker.
   


5. Do not leave any space between the speaker and door. Firmly hold together the 2 items while installing the rivet.
   

   Text in Illustration

   *1	Riveter
   *a	INCORRECT
   *b	CORRECT

Connect the connector.

Attach the 4 claws to install the rear door outer glass weatherstrip.

Install the rear door inner glass weatherstrip to the rear door trim board and fold down the 6 claws in the directions indicated by the arrows in the illustration.

Attach the 10 clips to install the rear door trim board.

Install the screw.

Install the door pull handle with the screw.

Connect the connector.

Attach the 2 claws and 2 clips to install the rear power window regulator switch assembly with rear door armrest base panel.