Rear Door Reassembly

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 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 32 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 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.

w/ Power Door Lock:
(HILUX_TGN26 RM00000138X00YX_01_0008.html)

w/o Power Door Lock:

1. 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}

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

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

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.

NOTICE:

Do not apply grease to the spring of the window regulator.

w/ Power Window:

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

2. 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}

   Text in Illustration

   *1	Temporary Bolt

   NOTICE:

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

3. Connect the connector.
   

w/o Power Window:

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

2. Install the rear door window regulator with the 2 bolts, and then tighten the temporary bolt.
   

   Torque:

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

   Text in Illustration

   *1	Temporary Bolt

   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	10.7 mm (0.421 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.

NOTICE:

Be careful not to damage the glass or glass channel.

Standard:

Area	Dimension
A	10.7 mm (0.421 in.)

w/ Power Window:

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

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

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

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

   NOTICE:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3003X.html).

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

w/o Power Window:

1. Temporarily install the rear door window regulator handle.
   

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

3. Remove the rear door window regulator handle.
   

Install the front side of the rear door glass run.

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

Standard:

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

Install the rear door glass by passing it through the cutout of the rear door panel in the direction indicated by the arrow in the illustration.

NOTICE:

Do not damage the door glass.

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

NOTICE:

Do not damage the door glass.

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

Install the rear door glass run together with the rear door window division bar with the 2 bolts.

Finish installing the rear door glass run.

w/ Rear Speaker:

1. Apply new butyl tape to the rear door panel.
   

2. 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.
   

   Text in Illustration

   *a	Reference Point

   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.
      

w/o Rear Speaker:

1. Apply new butyl tape to the rear door panel.
   

2. Pass the rear door inside locking cable and rear door lock remote control cable 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.
   

   Text in Illustration

   *a	Reference Point

   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 rear speaker assembly 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

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



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

   Text in Illustration

   *a	INCORRECT
   *b	CORRECT
   *1	Riveter

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

   *a	INCORRECT
   *b	CORRECT
   *1	Riveter

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 panel and fold down the 6 claws in the directions indicated by the arrows in the illustration.

Attach the 9 clips to install the rear door trim board.

Install the screw and clip.

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.

Temporarily install the rear door window regulator handle, fully close the window, and then remove the rear door window regulator handle.

Install the plate and snap ring to the rear door window regulator handle.

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

Standard:

Area	Specified Condition
A	18 to 42°