Rear Door - Reassembly

Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - DOOR / HATCH

REAR DOOR - REASSEMBLY

  • HINT:
Use the same procedure for the RH side and LH side.
The procedure listed below is for the LH side.
A bolt without a torque specification is shown in the standard bolt chart ().
1. INSTALL REAR DOOR WEATHERSTRIP LH
  • HINT:
  • When installing the rear door weatherstrip, heat the vehicle body and rear door weatherstrip using a heat light.
  • Standard:
  • ItemTemperature
    Vehicle Body40 to 60°C (104 to 140°F)
    Rear Door Weatherstrip20 to 30°C (68 to 86°F)
  • NOTICE:
  • Do not heat the vehicle body or rear door weatherstrip excessively.

w/ Spot Cover:

Using a heat light, heat the vehicle body surface.

Remove the double-sided tape from the vehicle body.

Wipe off any tape adhesive residue with cleaner.

Using a heat light, heat the vehicle body and a new rear door weatherstrip LH.

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

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

Attach the 21 clips to install a new rear door weatherstrip LH.

  • HINT:
If clips are damaged during installation, replace them.
Press the rear door weatherstrip LH firmly to install it.

w/o Spot Cover:

Attach the 21 clips to install the rear door weatherstrip LH.

  • HINT:
  • If clips are damaged during installation, replace them.
2. INSTALL REAR DOOR CHECK ASSEMBLY LH

Apply MP grease to the sliding areas of the rear door check assembly LH.

Install the rear door check assembly LH to the door panel with the 2 nuts.

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

Apply adhesive to the threads of the bolt.

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

Install the bolt.

  • Torque:
  • 27 N*m{ 275 kgf*cm, 20 ft.*lbf}
3. INSTALL REAR DOOR CHECK COVER LH (w/ Cover)
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the rear door check cover LH.

4. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Entry and Start System)

Install the door electrical key oscillator with the screw.

  • Torque:
  • 2.0 N*m{ 20 kgf*cm, 18 in.*lbf}
5. INSTALL NO. 4 ELECTRICAL KEY WIRE HARNESS (w/ Entry and Start System)

Connect the connector.

Attach the 2 clamps to install the No. 4 electrical key wire harness to the rear door outside handle frame sub-assembly LH.

6. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

Attach the 2 claws to install the rear door outside handle frame sub-assembly LH.

Using a T30 "TORX" wrench, install the rear door outside handle frame sub-assembly LH with the screw.

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

w/ Entry and Start System:

Attach the clamp.

7. INSTALL REAR NO. 2 DOOR OUTSIDE HANDLE PAD LH

Attach the 2 claws to install the rear No. 2 door outside handle pad LH.

8. INSTALL REAR NO. 1 DOOR OUTSIDE HANDLE PAD LH

Attach the 3 claws to install the rear No. 1 door outside handle pad LH.

9. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Insert the front end of the rear door outside handle assembly LH into the rear door outside handle frame sub-assembly LH.

  • NOTICE:
  • If the bellcrank lever is not pulled and held when installing the rear door outside handle assembly LH, the bellcrank lever will interfere with the rear door outside handle assembly LH and the release plate may be damaged

Insert the rear end of the rear door outside handle assembly LH into the rear door outside handle frame sub-assembly LH. Next, slide the rear door outside handle assembly LH toward the front of the vehicle to install it.

Using a T30 ''TORX'' socket, tighten the screw.

w/ Entry and Start System:

Connect the connector.

10. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH

Attach the claw to install the rear door outside handle cover LH.

Using a T30 ''TORX'' socket, install the rear door outside handle cover LH with the screw.

11. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the rear door inside locking cable assembly LH.

Text in Illustration
*Aw/o Double Lock
*Bw/ Double Lock
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 3 claws.

12. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

Install the rear door lock remote control cable assembly LH.

Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the claw.

13. INSTALL REAR DOOR LOCK ASSEMBLY LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.

Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.

Using a T30 ''TORX'' wrench, the 3 screws.

  • Torque:
  • 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}
14. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH
15. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH

Clean the vehicle body surface.

Using a heat light, heat the vehicle body surface.

Remove the double-sided tape from the vehicle body surface.

Wipe off any tape adhesive residue with cleaner.

Install a new window frame moulding.

Using a heat light, heat a new window frame moulding and the vehicle body surface.

Remove the peeling paper from the face of the window frame moulding.

  • HINT:
  • After removing the peeling paper, keep the exposed adhesive free from foreign matter.
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the clip and double-sided tape to install the window frame moulding.

  • HINT:
  • Press the window frame moulding firmly to install it.
16. INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the claw to install the belt moulding.

17. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

Apply MP grease to the sliding and rotating areas of the regulator motor.

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

  • Torque:
  • 5.4 N*m{ 55 kgf*cm, 48 in.*lbf}
  • HINT:
  • A new rear window regulator motor uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.
18. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

Text in Illustration
*1Temporary Bolt

Loosely install the temporary bolt onto the rear door window regulator sub-assembly LH.

Insert the rear door window regulator sub-assembly LH into the door panel. Use the temporary bolt to hang the rear door window regulator sub-assembly LH on the door panel.

  • NOTICE:
  • Be careful not to drop the rear door window regulator sub-assembly LH as it may become damaged.

Temporarily install the rear door window regulator sub-assembly LH with the 3 bolts.

Tighten the 4 bolts in the order shown in the illustration.

  • Torque:
  • 8.0 N*m{ 82 kgf*cm, 71 in.*lbf}
19. INSTALL REAR NO. 2 DOOR FRAME GARNISH LH

Attach a new clip to install the rear No. 2 door frame garnish LH.

20. INSTALL REAR DOOR FRAME GARNISH LH

Attach a new clip to install the rear door frame garnish LH.

21. INSTALL REAR DOOR GLASS CHANNEL FILLER (for Tempered Glass)
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the rear door glass channel filler onto the rear door glass.

Text in Illustration
*aFront Side
*b8.0 mm (0.327 in.)
22. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH (for Tempered Glass)

Apply soapy water to the inside of the rear door glass channel sub-assembly LH.

Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Using a plastic-faced hammer, tap the channel onto the glass to install the rear door glass channel sub-assembly LH.

  • NOTICE:
  • Be careful not to damage the glass or rear door glass channel sub-assembly LH.
Text in Illustration
*aFront Side
*b8.0 mm (0.327 in.)
23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Slide the rear door glass sub-assembly LH as shown in the illustration to install it.

24. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH

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

25. INSTALL REAR DOOR QUARTER WINDOW GLASS LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the rear door quarter window glass LH together with the rear door quarter window weatherstrip LH in the direction indicated by the arrow in the illustration.

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

Install the rear door rear lower window frame sub-assembly LH with the 2 bolts and screw.

27. INSTALL REAR DOOR GLASS RUN LH

Install the rear door glass run LH.

28. INSTALL REAR DOOR PANEL PROTECTOR LH

Attach the claw to install the rear door panel protector LH.

29. INSTALL REAR DOOR SERVICE HOLE COVER LH

Apply butyl tape to the door.

Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

  • NOTICE:
When installing the rear door service hole cover LH, pull the links and connectors through the rear door service hole cover LH.
There should be no wrinkles or folds after attaching the rear door service hole cover LH.
After attaching the rear door service hole cover LH, check the sealing quality.

Connect the 2 connectors.

Attach the 6 clamps.

Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the bolt as shown in the illustration.

  • Torque:
  • 8.4 N*m{ 86 kgf*cm, 74 in.*lbf}
30. INSTALL REAR SPEAKER SET (w/ Rear Speaker)
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Temporarily install the speaker by attaching the claw of the speaker to the door panel.

Install the speaker with the 3 screws.

  • NOTICE:
  • Do not touch the cone part of the speaker.

Connect the connector.

31. INSTALL REAR NO. 3 SPEAKER ASSEMBLY (for 14 Speakers)
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Align the speaker to the door position pins labeled A.

Install the speaker with the 2 screws.

  • NOTICE:
  • Do not touch the cone part of the speaker.

Attach the clamp and connect the connector.

32. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH

Install the rear door inside handle bezel LH to the trim board with the 6 screws.

33. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH

Attach the 2 claws to install the rear door inside handle sub-assembly LH.

34. INSTALL REAR INNER DOOR GLASS WEATHERSTRIP LH
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the rear inner door glass weatherstrip LH to the door panel.

35. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH

Connect the connector.

Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH to the rear door inside handle sub-assembly LH.

Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 4 claws and 9 clips to install the rear door trim board sub-assembly LH.

Install the 3 screws.

36. INSTALL ASSIST GRIP COVER LH

Attach the 9 claws to install the assist grip cover LH to the rear door trim board sub-assembly LH.

37. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 2 claws to install the regulator switch.

38. INSTALL REAR DOOR UPPER ARMREST BASE PANEL LH

Connect the connector.

Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 7 claws to install the armrest base panel.

39. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH

Attach the 4 claws to install the rear door inside handle bezel LH.

40. INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)
Rear Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the connector.

Attach the claw of the courtesy light to the rear door trim.

41. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH

Attach the 3 clamps and 7 clips to install the rear door outside moulding sub-assembly LH.

42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  • NOTICE:
  • When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().