Reassembly

DOOR / HATCH: REAR DOOR: REASSEMBLY

1. REPAIR INSTRUCTION

2. INSTALL NO. 2 BLACK OUT TAPE

3. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

4. INSTALL REAR DOOR UPPER OUTSIDE STRIPE

5. INSTALL REAR DOOR OUTSIDE STRIPE

6. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

7. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

8. INSTALL REAR DOOR PANEL CUSHION

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

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 door handle nut and claw.

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

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

10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 2 claws and 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.

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

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 as shown in the illustration.

(b) Engage the 4 claws as shown in the illustration.

15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

(a) Install the rear door lock remote control cable assembly as shown in the illustration.

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

16. INSTALL REAR DOOR LOCK ASSEMBLY

NOTICE:
* When reusing the removed rear door lock 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 assembly.

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

(b) Install a new door lock wiring harness seal to the rear door lock assembly.

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

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

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

17. INSTALL REAR DOOR CUSHION

(a) When reusing the rear door cushion:

(1) Clean the rear door cushion.

(2) Remove the double-sided tape from the rear door cushion.

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

(4) Apply new double-sided tape to the rear door cushion as shown in the illustration.

(b) Clean the rear door panel sub-assembly.

(c) Engage the 2 guides.

(d) Install the rear door cushion with the 2 bolts.

Text in Illustration

18. 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
A new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

19. 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 rear door window regulator assembly.

Text in Illustration

(d) Tighten the temporary bolt and 5 bolts.

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

20. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

(a) Connect the cable to the negative (-) battery terminal and the rear power window regulator motor connector.

(b) Connect the power window regulator switch assembly and move the rear door glass sub-assembly so that the door glass bolts can be seen.

(c) Disconnect the power window regulator switch assembly and rear power window regulator motor connector.

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

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

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

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

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

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

21. INSTALL REAR DOOR REAR GUIDE SEAL

(a) Install the temporary screw to the rear door rear guide seal.

(b) Temporarily install the rear door rear guide seal.

Text in Illustration

(c) Install the 2 screws.

(d) Tighten the temporary screw to install the rear door rear guide seal.

22. INSTALL REAR DOOR WINDOW GUIDE SUB-ASSEMBLY

(a) Install the screw.

(b) Install the rear door window guide sub-assembly with the bolt.

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

23. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.

24. INSTALL REAR DOOR WEATHERSTRIP

(a) Engage the 18 clips and install the rear door weatherstrip.

25. INSTALL REAR DOOR CHECK ASSEMBLY

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the rear door check assembly with the 3 bolts.

(A) - Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

(B) - Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

26. INSTALL REAR DOOR SERVICE HOLE COVER

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

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

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

Text in Illustration

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

(d) Connect the 2 connectors.

(e) Engage the clamp.

27. INSTALL REAR DOOR TRIM BRACKET

(a) Install the rear door trim bracket with the 2 screws.

28. INSTALL REAR DOOR SPEAKER COVER (for 4 Speakers)

(a) Using an air riveter or a hand riveter, install the rear door speaker cover with 3 new rivets.

Text in Illustration

NOTICE:
* Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
* Confirm that the rivet is seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any clearance between the rivet head and moulding.
* Do not leave any clearance between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

HINT
If the rivet cannot be cut, pull it once and cut it.

(b) Connect the connector.

29. INSTALL REAR SPEAKER ASSEMBLY (for 6 or 8 Speakers) Installation

30. INSTALL REAR DOOR FRAME GARNISH

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

31. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 8 Speakers) Installation

32. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 7 claws and install the rear door inner glass weatherstrip to the rear door trim board sub-assembly as shown in the illustration.

33. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly to the rear door inside handle.

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

34. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) for 8 Speakers:

(1) Connect the connector.

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

(c) Install the 2 screws.

(d) Remove the protective tape.

35. INSTALL REAR DOOR ARMREST COVER

(a) Install the rear door armrest cover.

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

(a) Connect the connector.

(b) Engage the 7 claws and 2 guides, and install the rear power window regulator switch assembly with rear door armrest base panel.

37. INSTALL DOOR ASSIST GRIP COVER

(a) Engage the 6 claws, 2 clips and 3 guides, and install the assist grip cover.

38. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

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

39. INITIALIZE POWER WINDOW CONTROL SYSTEM

Initialization

40. INSTALL REAR NO. 3 FLOOR BOARD Installation

41. INSTALL REAR DECK FLOOR BOX Installation

42. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) Installation