Reassembly (from 07/2011)

DOOR / HATCH: REAR DOOR (for Hatchback): REASSEMBLY

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

1. APPLY BODY GREASE

2. INSTALL NO. 2 BLACK OUT TAPE

HINT
Use the same procedure as for the LH side .

3. INSTALL REAR DOOR WEATHERSTRIP

(a) Engage the 29 clips and install the front door weatherstrip.

(b) Engage the 2 clips.

4. INSTALL REAR DOOR CHECK ASSEMBLY

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

(b) Install the rear door check onto the door panel with the 2 bolts.

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the front door check onto the body panel with the bolt.

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

5. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Apply MP grease to the sliding areas of the rear door outside handle frame.

(b) Slide the front door outside handle frame to install it.

Text in Illustration

(c) Engage the grommet and 2 claws.

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

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

6. INSTALL REAR DOOR OUTSIDE HANDLE REAR PAD

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

7. INSTALL REAR DOOR OUTSIDE HANDLE FRONT PAD

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

8. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

(a) Pushing the rear door outside handle in the direction of the arrow mark shown in the illustration, install the rear door outside handle.

9. INSTALL REAR DOOR OUTSIDE HANDLE COVER

(a) Engage the 2 claws and temporarily install the front door outside handle cover.

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

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

10. INSTALL REAR DOOR LOCK ASSEMBLY (w/ Power Door Lock) Installation (from 07/2011)

11. INSTALL REAR DOOR LOCK ASSEMBLY (w/o Power Door Lock) Installation (from 07/2011)

12. INSTALL REAR DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

HINT
Use the same procedure as for the LH side .

13. INSTALL NO. 1 SEPARATOR DOOR STIFFENER CUSHION

(a) Install the rear door No. 1 separator door stiffener cushion with the 2 bolts.

Torque : 6.3 Nm (64 kgf-cm, 55 in-lbf)

14. INSTALL REAR DOOR GLASS RUN

(a) Engage the 2 guides and install the rear door glass run.

(b) Install the clip.

15. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/ Power Window)

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

(b) Install the temporary bolt.

(c) Insert the rear door window regulator into the door panel. Use the temporary bolt to hang the rear door window regulator on the door panel.

Text in Illustration

(d) Tighten the 3 bolts and the temporary bolt in the order shown in the illustration.

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

(e) Connect the connector.

16. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/o Power Window)

(a) Tighten the 3 bolts in the order shown in the illustration.

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

17. INSTALL REAR DOOR GLASS CHANNEL FILLER

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

(b) Install the new rear door glass channel filler as shown in the illustration.

Text in Illustration

18. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY

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

(b) Using a plastic-faced hammer, tap the channel onto the glass to install the glass channel.

Text in Illustration

NOTICE:
* Be careful not to damage the glass or glass channel.
* Make sure the position of the rear door glass channel filler does not change.

19. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

(a) Insert the rear door glass into the rear door panel along the rear door glass run as indicated by the arrows in the order shown in the illustration.

NOTICE:
Do not damage the rear door glass.

(b) Slide the lower section of the rear door glass as indicated by the arrow as shown in the illustration.

20. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

(a) Engage the rear door window division bar to the rear door glass run.

(b) Install the rear door window division bar with the 3 bolts and nut.

Torque : 6.2 Nm (63 kgf-cm, 55 in-lbf)

21. 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) Install a new rear door service hole cover according to the reference points on the rear door panel.

Text in Illustration

HINT
Securely install the rear door service hole cover taking care to prevent wrinkles.

22. INSTALL REAR SPEAKER ASSEMBLY Installation (from 07/2011)

23. INSTALL REAR DOOR GLASS INNER WEATHERSTRIP

(a) Engage the 7 claws and install the rear door glass inner weatherstrip as shown in the illustration.

24. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 4 guides and install the rear door inside handle.

25. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

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

Text in Illustration

(b) Engage the 7 clips and install the rear door trim board.

(d) Engage the claw and close the cover.

26. INSTALL REAR DOOR ARMREST BASE UPPER PANEL (w/ Power Window)

(a) Connect the connector.

(b) Engage the 9 claws and 3 guides, and install the rear armrest base upper panel.

27. INSTALL REAR DOOR ARMREST BASE UPPER PANEL (w/o Power Window)

(a) Engage the 5 claws and 2 guides, and install the front armrest base upper panel.

28. INSTALL REAR DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)

(a) Install the window regulator handle plate.

Text in Illustration

(b) Open all the windows.

(c) Install the rear door window regulator handle with the clip at the angle shown in the illustration.

Text in Illustration

29. INSTALL REAR DOOR FRAME GARNISH

(a) Engage the guide.

(b) Engage the 2 clips and claw and install the rear door frame garnish.

30. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

31. INSPECT POWER WINDOW OPERATION (w/ Power Window)

Operation Check (from 07/2011)