Reassembly

DOOR / HATCH: REAR DOOR: REASSEMBLY

HINT
* Use the same procedure for both the RH and LH sides.
* The procedure described below is for the LH side.

1. REPAIR INSTRUCTION

2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

3. INSTALL REAR DOOR OUTSIDE STRIPE

4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

6. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

7. INSTALL REAR DOOR PANEL CUSHION

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

8. INSTALL REAR DOOR NO. 2 WEATHERSTRIP

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

9. 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 claw.

Text in Illustration

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

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

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

11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

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

12. 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.

NOTICE:
If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and the release plate will be damaged.

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

13. INSTALL REAR DOOR OUTSIDE HANDLE COVER

(a) Engage the claw and install the rear door outside handle cover.

(b) Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

14. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

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

(b) Engage the 3 claws.

15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

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

(b) Engage the claw.

16. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

NOTICE:
* When reusing the removed rear door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one.
* Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
* Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the rear door lock with motor assembly.

(a) Apply MP grease to the sliding parts of the rear door lock with motor assembly.

(b) When reusing the rear door lock with motor assembly:

(1) Install a new door lock wiring harness seal to the rear door lock with motor assembly.

(c) Insert the rear door lock with motor assembly to the rear door outside handle release plate, and set it to the rear door panel.

Text in Illustration

(d) Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock with motor assembly.

(e) Using a T30 "TORX" socket wrench, install the rear door lock with motor assembly with the 3 screws.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

17. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTICE:
The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.

(a) Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

HINT
When replacing the rear window regulator, a new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

18. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY

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

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

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

Text in Illustration

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

HINT
Tighten the bolts in the order shown in the illustration.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

19. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY

(a) Engage the guide.

(b) Install a new rear door inside panel reinforce sub-assembly with the 4 screws.

20. INSTALL REAR DOOR FRAME GARNISH

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

21. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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

22. INSTALL REAR DOOR QUARTER WINDOW GLASS

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

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

23. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY

(a) Install the rear door lower window frame sub-assembly with the screw and 2 bolts.

24. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.

25. INSTALL REAR DOOR WEATHERSTRIP

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

26. INSTALL REAR DOOR CHECK ASSEMBLY

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Bolt - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

Nut - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

27. INSTALL REAR DOOR SERVICE HOLE COVER

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

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

Text in Illustration

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

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

(d) Connect the connector.

28. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

(a) Install the rear door inner glass weatherstrip.

29. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.

30. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) Install the No. 1 door scuff plate clamp as shown in the illustration.

(b) Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

Text in Illustration

(d) Engage the 8 clips and install the rear door trim board sub-assembly.

(e) Install the 3 screws.

(f) If protective tape has been applied, remove it.

31. INSTALL REAR ARMREST ASSEMBLY

(a) Engage the 2 guides, 3 clips and 7 claws to install the rear armrest assembly.

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

(a) Connect the connector.

(b) Engage the 4 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.

33. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

(a) Engage the 3 claws to install the rear door inside handle bezel plug.

34. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Repair Instruction - Initialization

35. INSTALL LUGGAGE TRIM SERVICE HOLE COVER Installation

36. INSPECT POWER WINDOW OPERATION

Operation Check