Reassembly

DOOR / HATCH: REAR DOOR: REASSEMBLY

HINT
* Use the same procedure for the RH and LH sides.
* The procedure listed below is for the LH side.
1. INSTALL NO. 3 OUTSIDE MOULDING RETAINER Installation

2. INSTALL REAR DOOR OUTSIDE MOULDING LH Installation

3. INSTALL REAR DOOR OUTSIDE STRIPE LH

4. INSTALL REAR DOOR LOWER OUTSIDE STRIPE LH

5. INSTALL NO. 2 BLACK OUT TAPE LH

6. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING LH

7. INSTALL REAR DOOR BELT MOULDING LH

8. INSTALL REAR DOOR PANEL CUSHION

(a) Attach the claw to install a new door panel cushion.

9. INSTALL REAR DOOR WEATHERSTRIP LH

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

10. INSTALL REAR DOOR CHECK ASSEMBLY LH

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

(b) Install the door check to the door panel with the 2 nuts.

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

11. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

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

(b) Attach 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)

12. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

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

13. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

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

14. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH

(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.

15. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH

(a) Attach the claw to install the rear door outside handle cover.

(b) Using a T30 "TORX" socket wrench, install the screw.

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

16. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY LH

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

(b) Attach the 3 claws.

17. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

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

(b) Attach the claw.

18. INSTALL REAR DOOR LOCK ASSEMBLY LH Installation

19. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH Installation

20. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

(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.

(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)

(e) Connect the connector.

21. INSTALL REAR DOOR GLASS CHANNEL FILLER

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

(b) Install the rear door glass channel filler to the position shown in the illustration.

22. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY LH

(a) Apply soapy water to the channel filler side of the rear door glass channel sub-assembly.

(b) Using a plastic-faced hammer, install the rear door glass channel sub-assembly to the position shown in the illustration.

NOTICE:
To prevent damaging the rear door glass sub-assembly, be careful not to strike the channel with too much force.

23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

(a) Temporarily install the regulator switch assembly.

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

(c) Operate the regulator switch until the regulator reaches bottom dead center.

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

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

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

(f) Remove the regulator switch assembly.

(g) Install the front side of the glass run.

(h) Apply MP grease to the sliding areas of the glass channel as shown in the illustration.

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

24. INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP LH

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

25. INSTALL REAR DOOR QUARTER WINDOW GLASS LH

(a) 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.

26. INSTALL REAR DOOR FRAME GARNISH LH

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

27. INSTALL REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY LH

(a) Insert the rear door window rear lower frame sub-assembly from above.

(b) Install the rear door window rear lower frame sub-assembly to the glass run.

(c) Install the temporary bolt to the rear door window rear lower frame sub-assembly.

(d) Install the rear door window rear lower frame sub-assembly to the glass run.

(e) Install the rear door window rear lower frame sub-assembly.

(f) Install the screw.

(g) Install the 2 bolts.

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

(h) Tighten the temporary bolt to install the rear door window rear guide sub-assembly.

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

28. INSTALL REAR DOOR GLASS RUN LH

(a) Install the glass run.

29. INSTALL REAR DOOR SERVICE HOLE COVER LH

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

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

NOTICE:
* There should be no wrinkles or folds when installing attaching the service hole cover.
* After installing the service hole cover, check the seal quality.
(d) Connect the connector.

(e) Attach the 3 clamps to the rear door wire.

30. INSTALL REAR SPEAKER ASSEMBLY Installation

31. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY (w/ Personal Light) Installation

32. INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light) Installation

33. INSTALL REAR DOOR HOLE COVER

(a) Attach the 2 claws to install the rear door hole cover.

34. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY Installation

35. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP LH

(a) Attach the 3 claws to install the rear door inner glass weatherstrip as shown in the illustration.

36. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Install the clamp to the door panel.

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

(d) Attach the rear door trim board sub-assembly to the 4 claws of the rear door inner glass weatherstrip as shown in the illustration.

(e) Attach the 9 clips to install the rear door trim board sub-assembly.

(f) Install the 3 screws.

(g) Attach the 4 claws to install the 2 hole covers.

37. INSTALL REAR DOOR INSIDE HANDLE BEZEL LH

(a) Attach the 3 claws to install the door inside handle bezel.

38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

39. INITIALIZE POWER WINDOW CONTROL SYSTEM

(a) Initialize the power window control system Installation.