Toyota 4Runner manuals

Toyota 4Runner: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for both the RH and LH sides.
  • The procedure listed below is for the LH side.

PROCEDURE

1. INSTALL NO. 3 OUTSIDE MOULDING RETAINER


2. INSTALL REAR DOOR OUTSIDE MOULDING LH


3. INSTALL REAR DOOR OUTSIDE MOULDING LH (w/ Intuitive Parking Assist System)


4. INSTALL REAR DOOR OUTSIDE STRIPE LH


5. INSTALL REAR DOOR LOWER OUTSIDE STRIPE LH


6. INSTALL NO. 2 BLACK OUT TAPE LH


7. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH


8. INSTALL REAR DOOR BELT MOULDING LH


9. INSTALL REAR DOOR PANEL CUSHION

(a) Attach the claw to install a new rear door panel cushion.


10. INSTALL REAR DOOR WEATHERSTRIP LH

(a) Attach the 20 clips to install the rear door weatherstrip LH.


11. INSTALL REAR DOOR CHECK ASSEMBLY LH

(a) Apply a few drops of adhesive to 2 or 3 threads of the bolt.

Text in Illustration

*1

Adhesive

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

NOTICE:

Install the bolt within 3 minutes of applying adhesive.


(b) Install the rear door check assembly LH to the rear door panel with the 2 nuts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}


(c) Install the rear door check assembly LH to the vehicle body with the bolt.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

12. 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.

(b) Attach the door handle nut and claw.


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

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

13. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

(a) Attach the 2 claws to install the rear door rear outside handle pad.


14. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

(a) Attach the 3 claws to install the rear door front outside handle pad.


15. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) Insert the front end of the rear door outside handle assembly LH into the rear door outside handle frame sub-assembly LH.

NOTICE:

If the bell crank lever is not pulled and held when installing the rear door outside handle assembly LH, the bell crank lever will interfere with the rear door outside handle assembly LH and the release plate will be damaged.


(b) Insert the rear end of the rear door outside handle assembly LH into the rear door outside handle frame sub-assembly. Next, slide the rear door outside handle assembly LH toward the front of the vehicle to install it.

(c) Move the lever back in the direction indicated by the arrow in the illustration to lock the rear door outside handle assembly LH.


16. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH

(a) Attach the claw to install the rear door outside handle cover LH.


(b) Using a T30 "TORX" socket wrench, install the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

17. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Install the rear door inside locking cable assembly LH to the rear door lock assembly LH.


(b) Attach the 3 claws to close the cover.


18. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Install the rear door lock remote control cable assembly LH to the rear door lock assembly LH.


(b) Attach the claw to close the cover.


19. INSTALL REAR DOOR LOCK ASSEMBLY LH


20. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY LH


21. 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) Install the temporary bolt to the rear door window regulator sub-assembly LH.

(c) Temporarily install the rear door window regulator sub-assembly LH.

Text in Illustration

*1

Temporary Bolt


(d) Tighten the temporary bolt and 3 bolts to install the rear door window regulator sub-assembly LH.

HINT:

Tighten the bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(e) Connect the connector.

22. INSTALL REAR DOOR GLASS CHANNEL FILLER

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

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

Standard

Area

Specified Condition

A

6.8 mm (0.268 in.)

B

6.7 mm (0.264 in.)

Text in Illustration

*a

Front Side

*b

Rear Side


23. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH

(a) Apply soapy water to the rear door glass channel filler side of the rear door glass channel sub-assembly LH.

(b) Using a plastic-faced hammer, install the rear door glass channel sub-assembly LH to the position shown in the illustration.

Standard

Area

Specified Condition

A

6.8 mm (0.268 in.)

B

6.7 mm (0.264 in.)

Text in Illustration

*a

Front Side

*b

Rear Side

NOTICE:

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


24. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH

(a) Connect the rear power window regulator switch assembly.

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

(c) Operate the rear power window regulator switch assembly until the rear door window regulator sub-assembly LH reaches bottom dead center.


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

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).


(e) Disconnect the rear power window regulator switch assembly.

(f) Install the front side of the rear door glass run LH.

(g) Apply MP grease to the sliding areas of the rear door glass channel sub-assembly LH as shown in the illustration.

Text in Illustration

*a

5.0 mm (0.197 in.)

*b

157 mm (6.181 in.)

*c

5.0 mm (0.197 in.)

MP grease

(h) Slide the rear door glass sub-assembly LH as shown in the illustration to install it.


25. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH

(a) Install the rear door quarter window weatherstrip LH to the rear door quarter window glass LH.

26. INSTALL REAR DOOR QUARTER WINDOW GLASS LH

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


27. INSTALL REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY LH

(a) Install the temporary bolt to the rear door window rear lower frame sub-assembly LH.

Text in Illustration

*1

Temporary Bolt


(b) Temporarily install the rear door window rear lower frame sub-assembly LH to the rear door panel.

(c) Install the screw.

(d) Install the 2 bolts.

Torque:

6.2 N·m {63 kgf·cm, 55 in·lbf}

(e) Tighten the temporary bolt to install the rear door window rear lower frame sub-assembly LH.

Torque:

6.2 N·m {63 kgf·cm, 55 in·lbf}

28. INSTALL REAR DOOR GLASS RUN LH

(a) Install the rear door glass run LH.


29. INSTALL REAR DOOR FRAME GARNISH LH

(a) Attach the clip to install a new rear door frame garnish LH.


30. INSTALL REAR DOOR SERVICE HOLE COVER LH

(a) Apply a new butyl tape to the rear door panel.

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


(c) Install the rear door service hole cover LH according to the reference points on the rear door panel.

Text in Illustration

*1

Reference Point

NOTICE:

Securely install the rear door service hole cover LH preventing wrinkles and air bubbles.

(d) Connect the connector.

(e) Attach the 3 clamps and rear door wire.

31. INSTALL REAR SPEAKER ASSEMBLY


32. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY (w/ Intuitive Parking Assist System)


33. INSTALL COURTESY LIGHT ASSEMBLY


34. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY


35. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH

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


36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Attach the claw to install the clamp.


(b) Connect the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH as shown in the illustration.


(c) Connect the connector.


(d) Attach the rear door trim board sub-assembly LH to the 4 claws of the rear door inner glass weatherstrip LH as shown in the illustration.


(e) Attach the reference boss.

Text in Illustration

*1

Reference Boss

(f) Attach the 9 clips to install the rear door trim board sub-assembly LH.


(g) Install the 3 screws.

(h) Attach the 4 claws to install the 2 door armrest caps.


37. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH

(a) Attach the 3 claws to install the rear door inside handle bezel LH.


38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).


39. INITIALIZE POWER WINDOW CONTROL SYSTEM

(See page )


Adjustment
ADJUSTMENT CAUTION / NOTICE / HINT HINT: Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts installed. ...

Exterior Panels / Trim
...

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Disposal
DISPOSAL CAUTION / NOTICE / HINT CAUTION: Before performing pre-disposal deployment of any SRS part, review and closely follow all applicable environmental and hazardous material regulations. Pre-disposal deployment may be considered hazardous material ...

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