Lexus ES: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

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.

2. INSTALL REAR DOOR PANEL CUSHION

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

3. INSTALL REAR DOOR NO. 3 WEATHERSTRIP

(a) 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.

(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

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4. INSTALL REAR DOOR NO. 2 WEATHERSTRIP

(a) Engage the 6 clips to install the rear door No. 2 weatherstrip.

5. REPAIR INSTRUCTION

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6. INSTALL REAR INNER BLACK OUT TAPE

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7. INSTALL UPPER INNER BLACK OUT TAPE

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8. INSTALL FRONT INNER BLACK OUT TAPE

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9. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

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10. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

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11. INSTALL REAR DOOR BELT MOULDING SUB-ASSEMBLY

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12. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

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13. 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}

14. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

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

15. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

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

16. INSTALL REAR DOOR OUTSIDE HANDLE COVER

(a) Engage the 2 claws.

(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}

17. 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

(d) Engage the clamp.

(e) Connect the connector.

(f) Engage the 2 claws as shown in the illustration.

Engage in this Direction

18. INSTALL REAR DOOR LOCK CHILD PROTECTION COVER

(a) Engage the 6 claws to install the rear door lock child protection cover.

19. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

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20. 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.

21. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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

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

(c) Turn the engine switch (for Gasoline Model) or power switch (for HV Model) on (IG).

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

(e) Turn the engine switch (for Gasoline Model) or power switch (for HV Model) off.

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

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

(h) 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

(i) Install the rear door glass sub-assembly with the 2 bolts. Torque: 5.5 N·m {56 kgf·cm, 49 in·lbf}

(j) Install the hole plug.

22. INSTALL REAR DOOR QUARTER WINDOW GLASS SUB-ASSEMBLY

(a) Temporarily install the rear door quarter window glass sub-assembly as shown in the illustration.

Install in this Direction

(b) Install the rear door quarter window glass sub-assembly with the screw (A) and screw (B).

	Screw (A)
	Screw (B)

23. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

(a) Install the 2 bolts. Torque: 6.75 N·m {69 kgf·cm, 5 ft·lbf}

(b) Install the rear door window division bar sub-assembly with the screw.

24. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.

25. INSTALL REAR DOOR WEATHERSTRIP

(a) 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.

(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 22 clips and install the rear door weatherstrip.

Double-sided Tape

(d) Engage the 2 clips.

(e) Engage the clip.

26. 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}

27. INSTALL REAR DOOR FRAME GARNISH

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

28. INSTALL REAR DOOR PANEL PROTECTOR

(a) Install the rear door panel protector as shown in the illustration.

Install in this Direction

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

29. INSTALL REAR DOOR NO. 2 VENT SEAL

(a) Install the rear door No. 2 vent seal as shown in the illustration.

Install in this Direction

30. INSTALL REAR DOOR NO. 2 SERVICE HOLE COVER

(a) Engage the 2 guides and install the rear door No. 2 service hole cover to the rear door inner glass weatherstrip as shown in the illustration.

Install in this Direction

(b) Install the rear door inner glass weatherstrip with the rear door No. 2 service hole cover as shown in the illustration.

Install in this Direction

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

31. INSTALL REAR DOOR NO. 1 SERVICE HOLE COVER

(a) Align the alignment marks and install the rear door No. 1 service hole cover.

*a Alignment Mark

32. INSTALL REAR DOOR SERVICE HOLE COVER

(a) Engage the 7 clips to install the rear door service hole cover.

(b) Engage the guide.

	Screw (A)
	Screw (B)

(c) Install the bracket with the 2 screws (A) and screw (B).

(d) Engage the 5 clamps.

(e) Connect the connector.

33. INSTALL CURTAIN HOOK (w/ Rear Door Sunshade)

HINT:

Use the same procedure for both curtain hooks.

(a) Engage the 2 claws.

(b) Engage the pin to install the curtain hook as shown in the illustration.

34. INSTALL REAR SIDE CURTAIN ASSEMBLY (w/ Rear Door Sunshade)

(a) Engage the 2 clips to install the rear side curtain assembly as shown in the illustration.

Install in this Direction

35. INSTALL REAR DOOR LOCK CONTROL KNOB BEZEL

(a) Install the rear door lock control knob bezel as shown in the illustration.

Install in this Direction

36. INSTALL REAR DOOR DOOR LOCKING HOLDER

(a) Install the rear door door locking holder as shown in the illustration.

Install in this Direction

(b) Install the screw.

37. INSTALL REAR CURTAIN SUB-ASSEMBLY (w/ Rear Door Sunshade)

(a) Engage the 3 guides.

(b) Install the rear curtain sub-assembly with the 6 screws.

38. INSTALL REAR DOOR WIRE (w/o Illumination)

(a) w/ Sub Wire Harness: (1) Engage the claw and 3 clamps to install the rear door wire.

39. INSTALL REAR DOOR WIRE (w/ Illumination)

(a) Connect the connector to install the rear door wire.

40. INSTALL REAR DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY (w/ Illumination)

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41. INSTALL REAR SPEAKER ASSEMBLY

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42. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Install the rear door inside handle sub-assembly with the 3 screws.

43. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) Engage the 2 claws as shown in the illustration to connect the rear door inside lock/unlock knob locking cable to the rear door trim board sub-assembly.

Install in this Direction

(b) Connect the rear door lock open lever remote control cable as shown in the illustration.

Install in this Direction

(c) w/o Sub Wire Harness:

(1) Connect the connector.

(d) w/ Sub Wire Harness:

(1) Connect the connector.

(e) w/o Rear Door Sunshade:

(1) Engage the guide, 7 claws and 8 clips as shown in the illustration.

Install in this Direction

(f) w/ Rear Door Sunshade:

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

Install in this Direction

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

(h) Engage the 2 claws.

44. INSTALL COURTESY LIGHT ASSEMBLY

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45. INSTALL REAR DOOR TRIM UPPER PAD

(a) Engage the 2 claws to install the rear door trim upper pad.

46. INSTALL REAR DOOR ARMREST COVER

(a) Install the rear door armrest cover.

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

(a) Connect the connector.

(b) Engage the 3 guides, 4 claws and 2 clips 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

48. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for 2GR-FKS:

Click here

for A25A-FXS:

Click here

49. INITIALIZE POWER WINDOW CONTROL SYSTEM

for Gasoline Model:

Click here

for HV Model:

Click here

50. INSPECT POWER WINDOW OPERATION

for Gasoline Model:

Click here

for HV Model:

Click here

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