Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch (for Gasoline Model) or power switch (for HV Model) 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.

Click here

2. INSTALL REAR DOOR SILENCER PAD

(a) Clean the rear door panel surface.

(1) Remove any remaining butyl tape from the rear door panel.

(2) Wipe off any tape adhesive residue with cleaner.

(b) Remove the release paper from a new rear door silencer pad.

HINT:

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

(c) Install the rear door silencer pad as shown in the illustration.

Installation Position

Area

Measurement

a

20.3 mm (0.799 in.)

b

32.9 mm (1.30 in.)

c

15°

3. INSTALL REAR DOOR NO. 3 WEATHERSTRIP

(a) Clean the rear door panel.

(b) 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.

(c) Install the rear door No. 3 weatherstrip.

Double-sided Tape

-

-

4. REPAIR INSTRUCTION

Click here

5. INSTALL NO. 2 BLACK OUT TAPE

Click here

6. INSTALL NO. 3 BLACK OUT TAPE

Click here

7. INSTALL NO. 1 BLACK OUT TAPE

Click here

8. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

Click here

9. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

Click here

10. INSTALL REAR DOOR FRONT OUTSIDE SEAL

(a) Engage the guide to install the rear door front outside seal.

11. INSTALL REAR DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

Click here

12. INSTALL DOOR WINDOW FRAME MOULDING CLIP

(a) Engage the 2 claws to install the door window frame moulding clip.

13. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

Click here

14. INSTALL REAR DOOR NO. 2 WEATHERSTRIP

(a) Engage the 5 clips to install the rear door No. 2 weatherstrip.

15. INSTALL REAR DOOR PANEL CUSHION

(a) Engage the 4 claws to install 2 new rear door panel cushions.

16. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER

(a) Engage the 4 claws to install the rear door lock child protection cover.

17. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly.

(b) Engage the guide and claw as shown in the illustration.

Install in this Direction

(c) 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}

18. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 3 guides and claw to install the rear door rear outside handle pad.

19. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the guide and 2 claws to install the rear door front outside handle pad.

20. INSTALL REAR DOOR OUTSIDE HANDLE COVER

(a) Engage the claw.

(b) 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}

21. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

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

Install in this Direction

(b) 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.

(c) Move the lever as shown in the illustration and engage the 2 claws to secure the rear door outside handle assembly.

Engage in this Direction

22. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

Click here

23. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY

(a) Apply MP grease to the sliding parts of the rear door window regulator assembly.

(b) Temporarily install the temporary bolt to the rear door window regulator assembly.

(c) Temporarily install the rear door window regulator assembly with the 5 bolts.

*a

Temporary Bolt

(d) Tighten the temporary bolt and 5 bolts to install the rear door window regulator assembly.

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.

(f) Engage the 2 claws to install the rear door No. 3 service hole cover.

24. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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

(b) for Gasoline Model:

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

(c) for HV Model:

(1) Connect the cable to the negative (-) auxiliary battery terminal.

(d) for Gasoline Model:

(1) Turn the engine switch on (IG).

(e) for HV Model:

(1) Turn the power switch on (IG).

(f) Move the rear door window regulator assembly so that the door glass bolt holes can be seen.

(g) for Gasoline Model:

(1) Turn the engine switch off.

(h) for HV Model:

(1) Turn the power switch off.

(i) for Gasoline Model:

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

(j) for HV Model:

(1) Disconnect the cable from the negative (-) auxiliary battery terminal.

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

(l) Insert the rear door glass sub-assembly into the rear door panel as shown in the illustration.

NOTICE:

Do not damage the rear door glass sub-assembly.

Install in this Direction (1)

Install in this Direction (2)

(m) Install the rear door glass sub-assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(n) Install the hole plug.

25. INSTALL REAR DOOR REAR GUIDE SEAL

(a) Temporarily install the rear door rear guide seal as shown in the illustration.

Install in this Direction

(b) Install the rear door rear guide seal with the 2 screws.

26. INSTALL REAR DOOR WEATHERSTRIP

(a) Clean the rear door panel.

(b) Remove the release paper from a new rear door weatherstrip.

HINT:

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

(c) Engage the 21 clips and install the rear door weatherstrip.

Double-sided Tape

(d) Engage the clip.

27. INSTALL REAR DOOR CHECK ASSEMBLY

(a) Clean the bolt hole in the vehicle body.

(b) Clean the threads of the bolt.

(c) Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the rear door check assembly with the 2 nuts and bolt.

Nut

Bolt

Torque:

Bolt :

29 N·m {296 kgf·cm, 21 ft·lbf}

Nut :

8.0 N·m {82 kgf·cm, 71 in·lbf}

28. INSTALL REAR DOOR FRAME GARNISH

(a) Engage the 2 claws to install the rear door frame garnish.

29. INSTALL REAR DOOR REAR LOWER WINDOW FRAME SUB-ASSEMBLY

(a) Install the 2 bolts.

(b) Install the rear door rear lower window frame sub-assembly with the 2 screws.

30. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.

31. INSTALL HOLE PLUG

(a) Install the hole plug.

32. INSTALL REAR DOOR NO. 2 SERVICE HOLE COVER

(a) Install the rear door No. 2 service hole cover as shown in the illustration.

Install in this Direction

(b) Engage the clip to connect the rear door weatherstrip as shown in the illustration.

33. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 2 guides and install the rear door inner glass weatherstrip as shown in the illustration.

Install in this Direction (1)

Install in this Direction (2)

34. INSTALL REAR DOOR SERVICE HOLE COVER

(a) Engage the 9 clips to install the rear door service hole cover.

(b) Engage the 3 clamps.

(c) Connect the connector.

35. INSTALL REAR DOOR NO. 1 TRIM BRACKET

(a) Install the rear door No. 1 trim bracket with the screw.

36. INSTALL REAR SPEAKER ASSEMBLY

Click here

37. INSTALL REAR DOOR ORNAMENT

(a) Engage the 2 guides to install the rear door ornament as shown in the illustration.

Install in this Direction

38. INSTALL REAR DOOR PULL HANDLE

(a) Engage the guide and 4 claws as shown in the illustration.

Install in this Direction

(b) Install the rear door pull handle with the 2 screws.

39. INSTALL REAR DOOR TRIM COVER

(a) Engage the 2 guides to install the rear door trim cover as shown in the illustration.

Install in this Direction

(b) Engage the guide as shown in the illustration.

Install in this Direction

(c) Install the rear armrest assembly with rear door trim cover with the 9 screws.

40. INSTALL REAR DOOR TRIM BODY BRACKET

(a) Install the rear door trim body bracket with the 3 screws.

41. INSTALL REAR DOOR SPEAKER GRILLE SUB-ASSEMBLY

(a) Engage the 2 guides as shown in the illustration.

Install in this Direction

(b) Install the rear door speaker grille sub-assembly with the 2 screws.

42. INSTALL REAR NO. 2 SPEAKER ASSEMBLY

Click here

43. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 3 claws to install the rear door inside handle sub-assembly.

44. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) Connect the connector.

(b) 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.

*1

Rear Door Inside Lock/Unlock Knob Locking Cable

*2

Rear Door Lock Open Lever Remote Control Cable

Install in this Direction

(c) Engage the guide, 8 clips and 6 claws as shown in the illustration.

Install in this Direction

(d) Install the rear door trim board sub-assembly with the 3 screws.

45. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL

(a) Connect the connector.

(b) Engage the 3 claws to install the rear power window regulator switch assembly with rear door upper armrest base panel as shown in the illustration.

Install in this Direction

46. INSTALL REAR DOOR TRIM ASSEMBLY COVER

(a) Engage the 2 guides and claw to install the rear door trim assembly cover.

47. INSTALL REAR DOOR ARMREST COVER SUB-ASSEMBLY

(a) Engage the 3 claws to install the rear door armrest cover sub-assembly.

48. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for A25A-FXS:

Click here

for 2GR-FKS:

Click here

49. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for HV Model)

Click here

50. INITIALIZE POWER WINDOW CONTROL SYSTEM

for Gasoline Model:

Click here

for HV Model:

Click here

51. INSPECT POWER WINDOW OPERATION

for Gasoline Model:

Click here

for HV Model:

Click here

    Disassembly

    Exterior Panels / Trim

    See More:

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    Toyota Avalon (XX50) 2019-2022 Owners Manual

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