DSD Information System
Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Door / Hatch - Service Information (2 Of 2) >> Rear Door >> Reassembly [10/2022 - ] >> Procedure

Reassembly [10/2022 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

  2. INSTALL REAR DOOR DUST PROOF SEAL 
    1. Engage the 3 claws to install 3 new rear door dust proof seals.
      GTY897737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL REAR DOOR FRONT OUTSIDE SEAL 
    1. Engage the guide and 4 claws to install the rear door front outside seal.
      GTY897738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL REAR DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 6 clips to install the rear door No. 2 weatherstrip.
      GTY939296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL REAR DOOR UPPER OUTSIDE MOULDING PAD 

    Refer to PROCEDURE - Step 4 [09/2020 - 11/2024] , or refer to PROCEDURE - Step 4 [11/2024 - ]

  6. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  8. INSTALL REAR DOOR PANEL CUSHION 
    1. Engage the claw to install a new rear door panel cushion.
      GTY897742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR DOOR NO. 3 WEATHERSTRIP 
    1. Clean the rear door panel.
    2. Remove the release paper from a new rear door No. 3 weatherstrip.

      HINT: 

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

    3. Install the rear door No. 3 weatherstrip.
      GTY854822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape - -
  10. INSTALL DOOR WINDOW FRAME MOULDING CLIP 
    1. Engage the 2 claws to install the door window frame moulding clip.
      GTY897741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 1

  12. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 2

  13. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  14. INSTALL REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 1

  15. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER 
    1. Engage the 6 claws to install the rear door child protection cover.
      GTY897771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly.
    2. Engage the guide and claw as shown in the illustration.
      GTY846090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    3. 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) 

      GTY897769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 3 guides and claw to install the rear door rear outside handle pad.
      GTY897779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the guide and 2 claws to install the rear door front outside handle pad.
      GTY897777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the 2 claws.
      GTY897778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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) 

  20. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly as shown in the illustration.
      GTY887184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly, then slide the rear door outside handle assembly toward the front of the vehicle to install it.
    3. Move the lever as shown in the illustration and engage the 2 claws to lock the rear door outside handle assembly.
      GTY897780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 5

  22. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door window regulator assembly.
    2. Install the rear door window regulator assembly with the 6 nuts.
      GTY939299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Connect the connector.
  23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. Connect the rear power window regulator switch assembly.
    2. Connect the cable to the negative (-) auxiliary battery terminal.
    3. Turn the ignition switch to ON.
    4. Move the rear door window regulator assembly so that the door glass bolt holes can be seen.
    5. Turn the ignition switch off.
    6. Disconnect the cable from the negative (-) auxiliary battery terminal.
    7. Disconnect the rear power window regulator switch assembly.
    8. Insert the rear door glass sub-assembly into the rear door panel as shown in the illustration.
      GTY859209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
      NOTE:

      Do not damage the rear door glass sub-assembly.

    9. Install the rear door glass sub-assembly with the 2 bolts.

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

      GTY897763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the hole plug.
      GTY897760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP 
    1. Install the rear door quarter window weatherstrip from the rear door quarter window glass.
      GTY897761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REAR DOOR QUARTER WINDOW GLASS 
    1. Install the rear door quarter window glass as shown in the illustration.
      GTY894210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  26. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Install the rear door window division bar sub-assembly with the 2 bolts and screw.
      GTY880345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Screw
      Bolt

      Bolt 

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

      Screw 

      Torque: 3.1 N.m (32 kgf/cm, 27 in.lbf) 

  27. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
      GTY942711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REAR DOOR SERVICE HOLE COVER 
    1. Engage the 7 clips to install the rear door service hole cover.
      GTY897764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 clamps.
      GTY939266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
  29. INSTALL QUARTER WINDOW UPPER STOP 
    1. Install the quarter window upper stop as shown in the illustration.
      GTY879287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  30. INSTALL NO. 1 REAR DOOR VENT SEAL 
    1. Engage the 3 guides to install the No. 1 rear door front vent seal as shown in the illustration.
      GTY842092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  31. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Install the rear door inner glass weatherstrip as shown in the illustration.
      GTY943644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  32. INSTALL REAR DOOR WEATHERSTRIP 
    1. Clean the rear door panel.
      1. Remove any remaining double-sided tape from the rear door panel.
      2. Wipe off any tape adhesive residue with cleaner.
    2. Remove the release paper from a new rear door weatherstrip.

      HINT: 

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

    3. Engage the guide and 28 clips to install the rear door weatherstrip.
      GTY921434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  33. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Clean the bolt hole in the vehicle body.
    2. Clean the threads of the bolt.
    3. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the rear door check assembly with the 2 nuts and bolt.
      GTY910168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt

      Bolt 

      Torque: 27 N.m (275 kgf/cm, 20 ft.lbf) 

      Nut 

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

  34. INSTALL REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  35. INSTALL NO. 2 REAR DOOR FRAME GARNISH 
    1. Engage the 3 claws to install the No. 2 rear door frame garnish.
      GTY897628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a moulding remove or equivalent, pull out the rear door quarter window weatherstrip from under the No. 2 rear door frame garnish.
      GTY867125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL REAR DOOR FRAME GARNISH 
    1. Engage the 2 guides as shown in the illustration.
      GTY898562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the clip to install the rear door frame garnish.
  37. INSTALL CURTAIN HOOK (w/ Rear Door Sunshade) 

    HINT: 

    Use the same procedure for both curtain hooks.

    1. Engage the 2 claws to install the curtain hook as shown in the illustration.
      GTY876185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the pin as shown in the illustration.
      GTY897733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL REAR CURTAIN SUB-ASSEMBLY (w/ Rear Door Sunshade) 
    1. Engage the 3 guides.
      GTY897596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear curtain sub-assembly with the 7 screws.
  39. INSTALL REAR DOOR ARMREST COVER 
    1. Engage the claw to install the rear door armrest cover as shown in the illustration.
      GTY869478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 3 claws to install the rear door inside handle sub-assembly.
      GTY897597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the rear door lock open lever remote control cable and rear door inside lock/unlock knob locking cable to the rear door inside handle sub-assembly as shown in the illustration.
      GTY841544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Door Inside Lock/Unlock Knob Locking Cable
      *2 Rear Door Lock Open Lever Remote Control Cable
      Install in this Direction
    2. w/ Illumination:
      1. Connect the connector.
        GTY939265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Engage the clamp.
    3. Engage the guide, 4 claws and 9 clips as shown in the illustration.
      GTY916035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    4. Install the rear door trim board sub-assembly with the 3 screws.
      GTY939276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the claw as shown in the illustration.
      GTY897652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL REAR DOOR INSIDE HANDLE BEZEL 
    1. Engage the 3 claws to install the rear door inside handle bezel.
      GTY897658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL 
    1. Connect the connector.
    2. Engage the 5 guides, 2 claws and 2 clips to install the rear power window regulator switch assembly with rear door upper armrest base panel.
      GTY897656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    for T24A-FTS:

    Refer to PROCEDURE - Step 4 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 4 [11/2023 - ]

    for A25A-FXS:

    Refer to PROCEDURE - Step 2 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 2 [11/2023 - ]

  45. INSTALL BATTERY SERVICE HOLE COVER (for HV Model) 

    Refer to PROCEDURE - Step 3 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 3 [11/2023 - ]

  46. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    Refer to INITIALIZATION [12/2019 - ]

  47. INSPECT POWER WINDOW OPERATION 

    Refer to OPERATION CHECK [12/2019 - ]

Diesel-Data.com