Rear Door Reassembly

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.

Refer to the illustration to position a new rear door outside stripe.

Reference Value:

Area	Specified Condition
A	+/-1.0 mm (0.039 in.) from End

Refer to the illustration to position a new black out tape.

Reference Value:

Area	Specified Condition
A	+/-1.0 mm (0.039 in.) from End

Refer to the illustration to position a new rear door lower outside stripe.

Reference Value:

Area	Specified Condition
A	+/-1.0 mm (0.039 in.) from End

Refer to the illustration to position a new No. 2 black out tape.

Reference Value:

Area	Specified Condition
A	2 to 4 mm (0.078 to 0.158 in.)
B	4 to 6 mm (0.157 to 0.236 in.)

Clean the vehicle body surface.

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

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

3. Wipe off any tape adhesive residue with cleaner.
   

Install a new rear door front window frame moulding.

1. Using a heat light, heat a new rear door front window frame moulding and the vehicle body surface.
   

2. Remove the peeling paper from the face of the rear door front window frame moulding.
   

   HINT:

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

3. Attach the clip and double-sided tape to install the rear door front window frame moulding.
   

   HINT:

   Press the rear door front window frame moulding firmly to install it.

Install a new door window frame moulding clip.

Attach the 7 claws to install the rear door belt moulding.

Attach the clip to install a new door panel cushion.

Attach the 6 clips and guide to install the rear door No. 2 weatherstrip.

Attach the 19 clips and guide to install the rear door weatherstrip.

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

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

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

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

Attach the door handle nut and claw.

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

Torque:

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

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

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

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

NOTICE:

If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and the release plate will be damaged.

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

Move the lever in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

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

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 assembly.

Attach the 3 claws.

Install the rear door lock remote control cable assembly.

Attach the claw.

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

Text in Illustration

*A	w/o Double Locking System
*B	w/ Double Locking System
	Slide

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

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

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

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

Torque:

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

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

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}

HINT:

A new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

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

Install the temporary bolt to the rear door window regulator assembly.

Temporarily install the rear door window regulator assembly with the temporary bolt.

Temporarily install the 3 bolts, and then tighten the temporary bolt and 3 bolts.

HINT:

Tighten the bolts in the order shown in the illustration.

Torque:

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

Apply soapy water to a new rear door glass channel filler.

Standard:

Area	Specified Condition
A	21 mm (0.827 in.)
B	22.5 mm (0.886 in.)

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

Apply soapy water to a new rear door glass channel sub-assembly.

Standard:

Area	Specified Condition
A	21 mm (0.827 in.)
B	22.5 mm (0.886 in.)

NOTICE:

To prevent damaging the rear door glass sub-assembly, be careful not to strike the channel with too much force.

Install the rear door glass channel sub-assembly to the position shown in the illustration.

Connect the cable to the negative (-) battery terminal and rear power window regulator motor connector.

Connect the power window regulator switch assembly and move the arm of the regulator so that the roller on the arm can be seen through the service hole.

Disconnect the power window regulator switch assembly and rear power window regulator motor connector.

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

NOTICE:

1. After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (LandCruiser RM000003YMD00TX.html).
   
2. When disconnecting the cable, some systems need to be initialized after the cable is reconnected (LandCruiser RM000003YMF011X.html).
   

Insert the rear door glass sub-assembly into the rear door panel along the rear door glass run as indicated by the arrow in the illustration.

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

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

Attach the clip to install a new door frame garnish.

Insert the rear door window division bar sub-assembly from above.

Install the rear door window division bar sub-assembly to the glass run.

Install the temporary bolt to the rear door window division bar sub-assembly.

Install the rear door window division bar sub-assembly.

Install the 2 bolts and screw.

Tighten the temporary bolt to install the rear door window division bar sub-assembly.

Install the glass run.

Apply new butyl tape to the rear door panel.

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

Attach the rear door service hole cover using to the reference points on the rear door panel.

NOTICE:

1. There should be no wrinkles or folds after attaching the service hole cover.
   
2. After attaching the service hole cover, check the seal quality.
   

Connect the connector.

Attach the 2 clamps to the rear door wire.

Temporarily install the speaker by attaching the 2 claws of the speaker to the door panel.

Install the rear speaker set with the 3 screws in the order shown in the illustration.

NOTICE:

Do not touch the cone of the speaker.

Connect the connector.

Attach the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

Install the 2 screws.

Install the 8 screws to the rear door armrest.

Align the speaker with the door position pins labeled A.

Install the rear No. 2 speaker with the 2 screws.

NOTICE:

Do not touch the cone of the speaker.

Turn the light in the direction indicated by the arrow to install it.

Attach the clamp.

Connect the connector.

Connect the connector.

Attach the claw to install the light.

Attach the 2 claws to install the rear reflex reflector assembly.

Attach the 2 claws to install the rear power window regulator switch assembly.

Attach the 3 claws to install the rear door inner glass weatherstrip as shown in the illustration.

Install the clamp to the door panel.

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

Connect each connector.

Attach the rear door trim board sub-assembly by attaching the 4 claws of the rear door inner glass weatherstrip as shown in the illustration.

Attach the 9 clips and install the rear door trim board sub-assembly.

Install the 3 screws.

Attach the 8 claws to install the assist grip cover.

Attach the 3 claws to install the door inside handle bezel.

Initialize the power window control system (LandCruiser RM000003YMF011X.html).