| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM100000001QT6W |
| Model Year Start: 2021 | Model: RAV4 | Prod Date Range: [08/2020 - ] |
| Title: DOOR / HATCH: REAR DOOR: REASSEMBLY; 2021 - 2024 MY RAV4 RAV4 HV [08/2020 - ] | ||
REASSEMBLY
CAUTION / NOTICE / HINT
HINT:
- Use the same procedure for the RH and LH sides.
- The procedure below is for the LH side.
PROCEDURE
1. INSTALL HOLE PLUG
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(a) Install the hole plug. HINT: Use the same procedure described for the other side. |
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2. INSTALL REAR DOOR PANEL CUSHION
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(a) Attach the claw and install the rear door panel cushion. |
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3. INSTALL SCREW GROMMET
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(a) Attach the claw and install the screw grommet. HINT: Use the same procedure described for the other side. |
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4. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH
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(a) Install the rear door lock child protection cover LH. |
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5. INSTALL REAR DOOR PANEL PROTECTOR LH
Click here
![2019 - 2024 MY RAV4 RAV4 HV [11/2018 - ]; EXTERIOR PANELS / TRIM: REAR DOOR OUTSIDE MOULDING: INSTALLATION+](/t3Portal/stylegraphics/info.gif)
6. INSTALL OUTSIDE MOULDING SET LH (for Off Road Package)
Click here
7. INSTALL OUTSIDE MOULDING SET LH (except Off Road Package)
Click here
8. INSTALL REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY LH
Click here
9. INSTALL REAR DOOR NO. 5 WEATHERSTRIP LH
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(a) Attach the clip and install the rear door No. 5 weatherstrip LH. |
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10. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING LH
Click here
11. INSTALL REAR DOOR WINDOW FRAME MOULDING LH (REAR PILLAR SIDE)
Click here
12. INSTALL DOOR WINDOW FRAME MOULDING CLIP
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(a) Attach the claw to install a new door window frame moulding clip. |
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13. INSTALL REAR DOOR FRONT OUTSIDE SEAL LH
Click here
14. INSTALL REAR DOOR WINDOW FRAME MOULDING LH (CENTER PILLAR SIDE)
Click here
15. INSTALL REAR DOOR WEATHERSTRIP LH
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(a) Attach the clip and install the rear door weatherstrip LH. |
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(b) Attach the clip and install the clip. |
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(c) Check that the rear door weatherstrip LH is securely installed to the rail of the rear door upper window frame moulding LH as shown in the illustration. NOTICE: If the rear door weatherstrip LH is not securely installed, water may leak into the vehicle. |
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16. INSTALL REAR DOOR CHECK ASSEMBLY LH
(a) When reusing a bolt (B):
(1) Clean the threads of the bolt with non-residue solvent.
(2) Apply adhesive to the threads of the bolt.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
(b) Install the rear door check assembly LH to the door panel with the 2 bolts (A).
Torque:
5.5 N·m {56 kgf·cm, 49 in·lbf}
(c) Install the rear door check assembly LH to the body panel with the bolt (B).
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Bolt (A) |
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Bolt (B) |
Torque:
30 N·m {306 kgf·cm, 22 ft·lbf}
17. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
(a) Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly LH.
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(b) Attach the guide as shown in the illustration. |
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(c) Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly LH with the "TORX" screw.
Torque:
4.0 N·m {41 kgf·cm, 35 in·lbf}
18. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD
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(a) Attach the guide and install the rear door rear outside handle pad. |
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19. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD
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(a) Attach the claw and guide to install the rear door front outside handle pad. |
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20. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
(a) Attach the claw and install the rear door outside handle cover LH as shown in the illustration.
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Install in this Direction |
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(b) Using a T30 "TORX" socket wrench, install the rear door outside handle cover LH with the "TORX" screw. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf} |
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21. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH
(a) Install the rear door outside handle assembly LH by pushing and sliding it in the direction indicated by the arrow shown in the illustration.
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Install in this Direction |
(b) Attach the holder as shown in the illustration.
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*1 |
Holder |
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Install in this Direction |
(c) w/ Smart Key System:
(1) Attach the claw to connect the connector and connector cover.
(2) Attach the claw and close the connector cover as shown in the illustration.
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Install in this Direction |
22. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY
Click here
23. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
Click here
24. INSTALL DOOR LOCK WIRING HARNESS SEAL
(a) When reusing rear door lock with motor assembly LH:
Click here
25. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY LH
Click here
26. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
Click here
27. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
(a) Apply MP grease to the sliding parts of the rear door window regulator sub-assembly LH.
(b) Pull in the rear door window regulator sub-assembly LH through the service hole as shown in the illustration.
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Install in this Direction |
(c) Install the rear door window regulator sub-assembly LH with the 6 nuts in the order shown in the illustration.
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Nut |
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Connector |
Torque:
8.0 N·m {82 kgf·cm, 71 in·lbf}
NOTICE:
Do not damage the rear door panel with the rear door window regulator sub-assembly LH.
(d) Connect the connector.
28. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH
(a) Connect the power window regulator switch assembly connector.
(b) Connect the cable to the negative (-) auxiliary battery terminal.
(1) for A25A-FXS:
Click here
(2) for A25A-FKS:
Click here
(c) Turn the ignition switch to ON.
(d) Move the rear door window regulator sub-assembly LH until the installation bolts can be seen.
(e) Insert the rear door glass sub-assembly LH to the rear door panel in the shown in the illustration.
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Install in this Direction |
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(f) Install the rear door glass sub-assembly LH with the 2 bolts. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf} NOTICE: Be careful not to damage the rear door glass sub-assembly LH. |
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(g) Move the rear door window regulator sub-assembly LH until the open position.
(h) Turn the ignition switch off.
(i) Disconnect the cable from the negative (-) auxiliary battery terminal.
(1) for A25A-FXS:
Click here
(2) for A25A-FKS:
Click here
(j) Disconnect the power window regulator switch assembly connector.
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(k) Install the hole plug. |
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29. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH
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(a) Install the rear door quarter window weatherstrip LH to the rear door quarter window glass LH. |
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30. INSTALL REAR DOOR QUARTER WINDOW GLASS LH
(a) Install the rear door quarter window glass LH with rear door quarter window weatherstrip LH as shown in the illustration.
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Install in this Direction |
31. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH
(a) Install the rear door glass run LH to the rear door window division bar sub-assembly LH.
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Install in this Direction |
(b) Insert the rear door window division bar sub-assembly LH with rear door glass run LH into the rear door panel assembly in the direction indicated by the arrow shown in the illustration.
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Install in this Direction |
(c) Install the rear door window division bar sub-assembly LH with the 2 bolts.
Torque:
8.5 N·m {87 kgf·cm, 75 in·lbf}
(d) Pull back part of the rear door weatherstrip LH and install the screw as shown in the illustration.
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Pull back in this Direction |
32. INSTALL REAR DOOR GLASS RUN LH
(a) Install the rear door glass run LH as shown in the illustration.
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Install in this Direction (1) |
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Install in this Direction (2) |
HINT:
Install the rear door glass run LH so that the top of it aligns with the top of the rear door window division bar sub-assembly.
33. INSTALL REAR DOOR BELT MOULDING LH
Click here
34. INSTALL REAR DOOR FRAME GARNISH LH
(a) Attach the guide and install the rear door frame garnish LH in the direction indicated by the arrows, in the order shown in the illustration.
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Install in this Direction (1) |
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Install in this Direction (2) |
35. INSTALL REAR DOOR SERVICE HOLE COVER LH
(a) Apply new butyl tape to the rear door panel.
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*a |
Reference Point |
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Butyl Tape |
HINT:
- Begin applying the butyl tape from the reference point shown in the illustration.
- The butyl tape can be applied from either reference point.
(b) Pass the rear door lock remote control cable assembly and rear door inside locking cable assembly through a new rear door service hole cover LH.
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*1 |
Rear Door Lock Remote Control Cable Assembly |
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*2 |
Rear Door Inside Locking Cable Assembly |
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Install in this Direction |
(c) Align the top of the rear door service hole cover LH with the reference point on the rear door panel and install it.
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*a |
Reference Point |
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Butyl Tape |
(d) Align the bottom of the rear door service hole cover LH with the reference point on the rear door panel and install it.
NOTICE:
- Securely install the rear door service hole cover LH to prevent wrinkles and air bubbles.
- There should be no wrinkles or folds after installing the rear door service hole cover LH.
- After installing the rear door service hole cover LH, check the seal quality.
36. INSTALL REAR SPEAKER ASSEMBLY
Click here
37. INSTALL REAR DOOR REAR BELT SEAL LH
(a) Install the rear door rear belt seal LH as shown in the illustration.
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Install in this Direction |
(b) Attach the guide and install part of the rear door weatherstrip LH with the clip.
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Install in this Direction |
38. INSTALL REAR DOOR FRONT BELT SEAL LH
(a) Install the rear door front belt seal LH to the rear door inner glass weatherstrip LH as shown in the illustration.
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Install in this Direction |
39. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH
(a) Install the rear door inner glass weatherstrip LH with rear door front belt seal LH as shown in the illustration.
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Install in this Direction |
(b) Attach the guide and install part of the rear door weatherstrip LH with the clip.
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Install in this Direction |
40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH
(a) Temporarily install the rear door inside handle sub-assembly LH in the direction indicated by the arrow as shown in the illustration.
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Install in this Direction |
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(b) Attach the claw and clamp to install the rear door inside handle sub-assembly LH. |
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41. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
(a) Attach the clamp and connect the rear door inside locking cable assembly and rear door lock remote control cable assembly to the rear door inside handle sub-assembly LH in the direction of the arrow indicated in the illustration.
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*1 |
Rear Door Inside Locking Cable Assembly |
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*2 |
Rear Door Lock Remote Control Cable Assembly |
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Install in this Direction |
(b) Attach the claw and clip to install the rear door trim board sub-assembly LH in the direction indicated by the arrow shown in the illustration.
HINT:
Attach the claw and clip as shown in the illustration.
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Install in this Direction |
(c) Attach the clip and install the 3 screws as shown in the illustration.
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Install in this Direction |
(d) Remove the protective tape.
42. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
Click here
43. INSTALL REAR SEAT HEATER SWITCH (w/ Seat Heater Switch)
Click here
44. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL
(a) w/ Seat Heater Switch:
(1) Connect the 2 connectors.
(b) w/o Seat Heater Switch:
(1) Connect the connector.
(c) Attach the guide in the direction indicated by the arrow shown in the illustration.
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Install in this Direction |
(d) Attach the guide and claw to install the rear power window regulator switch assembly with rear door armrest base panel.
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Install in this Direction |
(e) Remove the protective tape.
45. INSTALL DOOR ASSIST GRIP COVER LH
(a) Attach the guide in the direction indicated by the arrow shown in the illustration.
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Install in this Direction |
(b) Attach the claw in the order shown in the illustration.
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Install in this Direction |
(c) Attach the clip and install the door assist grip cover LH.
(d) Remove the protective tape.
46. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH
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(a) Attach the claw and install the rear door inside handle bezel LH. |
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47. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
(a) for A25A-FXS:
Click here
(b) for A25A-FKS:
Click here
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click here
48. INSTALL BATTERY HOLE COVER (for HV Model)
Click here
49. INSTALL REAR NO. 2 FLOOR BOARD (for HV Model)
Click here
50. INSTALL DECK BOARD ASSEMBLY (for HV Model)
Click here
51. INITIALIZE POWER WINDOW CONTROL SYSTEM
Click here
52. CHECK POWER WINDOW CONTROL SYSTEM
Click here
53. CHECK POWER DOOR LOCK CONTROL SYSTEM
Click here
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