Slide Door: Overhaul

HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
On the RH side, use the same procedures as on the LH side.

REMOVE REAR DOOR WINDOW FRAME MOLDING REAR LH (See REAR DOOR WINDOW FRAME MOLDING REAR LH )
REMOVE REAR DOOR WINDOW FRAME MOLDING SUB-ASSY LH (See REAR DOOR WINDOW FRAME MOLDING SUB-ASSY LH )
REMOVE SLIDE DOOR WINDOW GARNISH LH
1. Fully open the slide door window.
2. Remove the glass run.
3. Using a screwdriver, disengage the clip and remove the garnish.
  HINT:
  
  Tape the screwdriver tip before use.
4. Using a screwdriver, disengage the 2 claws and remove the weatherstrip inner from the garnish.
HINT:

Tape the screwdriver tip before use.

Fig 1: Disengaging Clip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SIDE TRIM BOARD COVER REAR LH
1. Remove the 2 screws.
2. Using a screwdriver, disengage the 8 claws and remove the cover together with the window control switch.
  HINT:
  
  Tape the screwdriver tip before use.
3. Remove the 2 screws and window control switch.
Fig 2: Removing 2 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH
1. Remove the screw.
2. Using a screwdriver, disengage the 9 clips and remove the trim board.
  HINT:
  - Tape the screwdriver tip before use.
  - In order to prevent the door panel from being damaged, cover the areas with protective tape as indicated by arrow marks in the illustration.
  Fig 3: Disengaging 9 Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a clip remover, remove the 6 clips and weatherstrip No. 2.
4. Using a screwdriver, disengage the 11 claws and remove the weatherstrip inner from trim board.
  HINT:
  
  Tape the screwdriver tip before use.
5. w/Sunshade:
  Remove the sunshade.
  1. Remove the 7 screws and sunshade bezel.
  2. Remove the 4 screws and curtain.
  Fig 4: Removing 4 Screws & Curtain
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDE DOOR WINDOW ASSY LH
1. w/Sunshade:
  Remove the sunshade hook.
2. Remove the bolt and window frame.
  
  Fig 5: Removing Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt.
4. Loosen the nut.
5. Push the window frame rear lower in the direction indicated by the arrow mark in the illustration.
  
  Fig 6: Removing Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 2 hole plugs.
7. Move the window until the bolts appear in the service holes.
  NOTE:
  - Do not damage the window assy.
  - When the bolts are removed, the window assy may fall and become deformed.
8. Remove the 2 bolts and window.
Fig 7: Removing 2 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR GLASS WEATHERSTRIP ASSY OUTER LH (See REAR DOOR GLASS WEATHERSTRIP ASSY OUTER LH )
REMOVE SLIDE DOOR
1. Remove the rear door scuff plate (See REPLACEMENT ).
2. Remove the back door scuff plate (See REPLACEMENT ).
3. Remove the quarter trim pane (See REPLACEMENT ).
4. Remove the upper rail cushion from the rail upper.
5. Disconnect the 2 connectors from the body side and remove the bolt and wire.
  
  Fig 8: Removing Bolt & Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Open the quarter glass.
7. Using a screwdriver, disengage the clip and 2 claws, remove the rail end molding.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 9: Disengaging Clip & 2 Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the 2 bolts and bracket center No. 2.
  
  Fig 10: Removing 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the 2 nuts and open stop.
  
  Fig 11: Removing 2 Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Rotate the base of the slide door roller lower in the direction indicated by arrow in the illustration and then remove the roller from the cut area of the lower rail from the body side.
  
  Fig 12: Rotating Base Of Slide Door Roller Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Move the slide door rearward and then remove the slide door roller upper from the cut area in the rear part of the slide door rail upper.
  
  Fig 13: Moving Slide Door Rearward
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Move the slide door further rearward and then remove the slide door hinge center from the rear part of the slide door rail center. Then, remove the slide door.
Fig 14: Moving Slide Door Further Rearward
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDE DOOR RAILS
1. Remove the roof headlining (See REPLACEMENT ).
2. Remove the 2 bolts, 2 nuts and the rail upper.
3. Remove the 2 screws and the rear side rail.
4. Remove the 3 screws and the rail center.
REMOVE SLIDE DOOR ATTACHMENT CONTROL LH
1. Remove the 2 screws, bolt and inside handle.
  
  Fig 15: Removing Screws, Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connectors from the lock actuator and power window regulator motor.
3. Disengage the control cables.
4. Remove the 8 bolts and attachment control.
  
  Fig 16: Removing 8 Bolts & Attachment Control
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the nut and the window frame rear lower.
  NOTE: When the nut is removed, the window frame may fall and become deformed.
  
  HINT:
  
  Remove the window frame rear lower through the service hole.
  
  Fig 17: Removing Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the control rod.
7. Remove the 3 bolts and lock remote control.
  
  Fig 18: Removing 3 Bolts & Lock Remote Control
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the 2 screws and lock actuator.
  
  Fig 19: Removing 2 Screws & Lock Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the 3 screws and power window regulator motor.
  
  Fig 20: Removing 3 Screws & Power Window Regulator Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Remove the half stop control lever and door lock control bellcrank.
11. Remove the 4 bolts and window regulator.
Fig 21: Removing 4 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR STIFFENER CUSHION LH
1. Remove 2 hole plugs.
2. Remove the 2 screws, clip and stiffener cushion.
  HINT:
  
  Remove the stiffener cushion through the service hole.
3. Remove the 2 grommets and 2 clips.
Fig 22: Removing Grommets & Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR OUTSIDE HANDLE COVER LH
1. Remove the hole plug.
2. Using a Torx® socket wrench (T30), loosen the screw and remove the outside handle cover with the lock key cylinder installed.
Fig 23: Removing Hole Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH
1. Pushing and pulling the outside handle in the direction indicated by the arrow mark in the illustration, remove the outside handle.
2. Remove the outside handle pads front and rear.
Fig 24: Removing Rear Door Outside Handle Assy LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
1. Remove the open rod to the outside handle frame.
2. Using a Torx® socket wrench (T30), loosen the screw.
3. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration and remove it.
HINT:

Remove the outside handle frame through the service hole.

Fig 25: Removing Rear Door Outside Handle Frame Sub-Assy LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDE DOOR LOCK ASSY FRONT LH
1. Remove the 2 cables.
2. Using a Torx® socket wrench (T30), remove the 3 screws and lock.
HINT:

Remove the lock through the service hole.

Fig 26: Removing 3 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR LOCK ASSY LH
1. Remove the cable.
2. Using the Torx® socket wrench (T30), remove the 3 screws and lock.
HINT:

Remove the lock through the service hole.

Fig 27: Removing 3 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR DOOR WIRE SUB-ASSY LH
1. Remove the 2 screws.
2. Using a screwdriver, remove the 2 clips and door wire.
HINT:

Tape the screwdriver tip before use.

Fig 28: Removing 2 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDE DOOR FULL OPEN STOP LOCK ASSY LH
1. Disconnect the 2 cables.
2. Remove the 2 bolts and lock.
Fig 29: Removing 2 Bolts & Lock
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDE DOOR ROLLER ASSY LOWER LH
1. Remove the 3 bolts and roller.
Fig 30: Removing 3 Bolts & Roller
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDE DOOR HINGE ASSY CENTER LH
1. Remove the 3 bolts and hinge.
2. LH side:
  Remove the cover.
Fig 31: Removing 3 Bolts & Hinge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SLIDE DOOR ROLLER ASSY UPPER
1. Remove the 2 bolts and roller.
Fig 32: Removing 2 Bolts & Roller
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SLIDE DOOR ROLLER ASSY UPPER
1. Apply MP grease to the rotating areas of the roller.
2. Install the roller with the 2 bolts.
Torque: 13 N.m (130 kgf.cm, 10 ft.lbf)

Fig 33: Installing Roller With 2 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SLIDE DOOR HINGE ASSY CENTER LH
1. Apply MP grease to the rotating areas of the hinge.
2. Install the hinge with the 3 bolts.
Torque: 31 N.m (316 kgf.cm, 23 ft.lbf)

Fig 34: Installing Hinge With 3 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SLIDE DOOR ROLLER ASSY LOWER LH
1. Apply MP grease to the rotating areas of the roller.
2. Install the roller lower with the 3 bolts.
Torque: 31 N.m (316 kgf.cm, 23 ft.lbf)

Fig 35: Installing Roller Lower With 3 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SLIDE DOOR FULL OPEN STOP LOCK ASSY LH
1. Apply MP grease to the sliding and rotating areas of the lock.
2. Install the lock with the 2 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
3. Connect the 2 cables.
Fig 36: Installing Lock With 2 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR WIRE SUB-ASSY LH
1. Install the wire.
  NOTE: When installing the wire, push the areas where the clips are installed in order to prevent damage and deformation.
2. Install the 2 screws.
Fig 37: Installing 2 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR LOCK ASSY LH
1. Apply MP grease to the sliding and rotating areas of the lock.
2. Apply adhesive to the threads of the screws.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
3. Install the lock to the door panel with the 3 screws.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
  
  Fig 38: Installing Lock To Door Panel With 3 Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the cable.
INSTALL SLIDE DOOR LOCK ASSY FRONT LH
1. Apply MP grease to the sliding and rotating areas of the lock.
2. Apply adhesive to the threads of the screws.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
3. Install the lock front to the door panel with the 3 screws.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
  
  Fig 39: Installing Lock Front To Door Panel With 3 Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the 2 cables.
INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
1. Apply MP grease to the sliding and rotating parts of the outside handle frame.
2. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration.
3. Using a Torx® socket wrench (T30), install the outside handle frame with the screw.
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
  
  NOTE: Insert a cover between the nut and the door panel.
4. Install the open rod.
Fig 40: Installing Outside Handle Frame With Screw
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE ASSY LH
1. Install the outside handle pads front and rear.
2. Pushing the outside handle in the direction indicated by the arrow mark in the illustration, install the outside handle.
NOTE: If the release plate is not pulled and held when installing the outside handle, it will strike against with the outside handle and become damaged.

Fig 41: Installing Rear Door Outside Handle Assy LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
1. Using a Torx® socket wrench (T30), install the outside handle cover with the screw.
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
2. Install the hole plug.
Fig 42: Installing Hole Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR STIFFENER CUSHION LH
1. Install the 2 grommets and 2 clips.
2. Install the stiffener cushion with the clip and 2 screws.
Fig 43: Installing Rear Door Stiffener Cushion LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL SLIDE DOOR ATTACHMENT CONTROL LH

Temporarily install the window frame rear lower with the nut.
Move the window frame rear lower in the direction indicated by the arrow mark in the illustration.

Fig 44: Installing Window Frame Rear Lower With Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply MP grease to the sliding and rotating areas of the window regulator.
Install the window regulator with the 4 bolts.
Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
Install the half stop control lever and door lock control bell-crank.

Fig 45: Installing Window Regulator With 4 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the power window regulator motor with the 3 screws.
Torque: 5.5 N.m (58 kgf.cm, 49 in.lbf)

Fig 46: Installing Power Window Regulator Motor With 3 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply MP grease to the sliding and rotating areas of the lock remote control.
Install the lock remote control with the 3 bolts.
Torque: 5.5 N.m (58 kgf.cm, 49 in.lbf)

Fig 47: Installing Lock Remote Control With 3 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Apply MP grease to the sliding and rotating areas of the lock actuator.
Install the lock actuator with 2 screws.
Torque: 5.5 N.m (58 kgf.cm, 49 in.lbf)

Fig 48: Installing Lock Actuator With 2 Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the attachment control with the 8 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

Fig 49: Installing Attachment Control With 8 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the inside handle with the 2 screws and bolt.
Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)

Fig 50: Identifying Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the control cables and the wires.

Fig 51: Installing Control Cables & Wires

CAP COLOR REFERENCE

No.	Cap Color	Control
A	Gray	Rear Lock Cable
B	Black	Full Open Lock Cable
C	-	Half Open Stopper Cable
D	Green	Front Lock Cable
E	Yellow	Outside Handle Cable

INSTALL SLIDE DOOR RAILS
1. Install the rail center with the 3 screws.
  Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
2. Install the rear side rail with the 2 screws.
  Torque: 19.5 N.m (200 kgf.cm, 14 ft.lbf)
3. Install the rail upper with the 2 bolts and 2 nuts.
  Torque: 10 N.m (102 kgf.cm, 8 ft.lbf)
4. Install the roof headlining (See REPLACEMENT ).
INSTALL SLIDE DOOR
1. Put in the slide door hinge center from the rear part of the slide door rail center.
  
  Fig 52: Installing Slide Door
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Move the slide door forward and then put in the slide door roller upper into the cut area of the slide door rail upper.
  
  Fig 53: Moving Slide Door
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Rotate the base of the slide door roller lower in the direction indicated by arrow in the illustration and then put in the roller lower into the cut area of the rail lower of the body.
  
  Fig 54: Rotating Base Of Slide Door Roller Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the open stop with the 2 nuts.
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
  
  Fig 55: Installing Open Stop With 2 Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the bracket center No. 2 with the 2 bolts.
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
  
  Fig 56: Installing Bracket With 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the rail end molding.
7. Install the upper rail cushion to the rail upper.
  
  Fig 57: Identifying Claw & Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the wire with the bolt. (See Fig 58).
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
9. Connect the 2 connectors.
10. Install the quarter trim panel (See REPLACEMENT ).
11. Install the back door scuff plate (See REPLACEMENT ).
12. Install the rear door scuff plate (See REPLACEMENT ).
Fig 58: Installing Wire With Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SLIDE DOOR WINDOW ASSY LH
1. Open the door glass until the bolts appear in the service holes.
2. Install the window with the 2 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
3. Install the hole plug.
  
  Fig 59: Installing Window With 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Put the window frame rear lower in the original position and tighten the nut.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
5. Install the bolt.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 60: Installing Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the window frame with the bolt.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
7. Install the glass run.
Fig 61: Installing Window Frame With Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002