Rear Door: Reassembly

1. Apply MP grease to the sliding parts on the rear door outside handle frame sub-assembly.
2. Using a "torx" socket wrench (T30), install the rear door outside handle frame sub-assembly with the screw.

Fig 1: Installing Rear Door Outside Handle Frame Sub-Assembly With Screw

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1. Attach the 2 claws to install the rear door rear outside handle pad.

Fig 2: Installing Rear Door Rear Outside Handle Pad

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1. Attach the 3 claws to install the rear door front outside handle pad.

Fig 3: Installing Rear Door Front Outside Handle Pad

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1. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.
   Fig 4: Inserting Front End Of Rear Door Outside Handle Assembly

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   NOTE: If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and it will damage the release plate.
2. 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 to the front of the vehicle to install it.
3. Using a "torx" socket wrench (T30), install the rear door outside handle assembly with the screw.

Fig 5: Installing Rear Door Outside Handle Assembly With Screw

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1. Install the rear door outside handle cover with the claw.
2. Using a "torx" socket wrench (T30), install the rear door outside handle cover with the screw.

Fig 6: Installing Rear Door Outside Handle Cover With Claw

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1. Install the rear door inside locking cable assembly.
   Fig 7: Installing Rear Door Inside Locking Cable Assembly

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2. Engage the 3 claws.

Fig 8: Identifying Claws

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1. Install the rear door lock remote control cable assembly.
   Fig 9: Installing Rear Door Lock Remote Control Cable Assembly

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2. Engage the claw.

Fig 10: Identifying Claw

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1. Apply MP grease to the sliding parts on the rear door lock assembly.
2. Install a new door lock wiring harness sealing to the rear door lock assembly.
3. Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.
4. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.
5. Using a "torx" socket wrench (T30), install the rear door lock assembly with the 3 screws.

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

6. Connect the connector.

Fig 11: Connecting Connector

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1. Using a "torx" driver (T25), install the power window regulator motor assembly with the 3 screws.
   Fig 12: Locating Power Window Regulator Motor Assembly Screws

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   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   HINT:

   The new rear window regulator adopts a self-tapping method. The installation position of the regulator will be threaded when the self-tapping screw is inserted.

1. Apply MP grease to the sliding parts on the rear door window regulator sub-assembly.
2. Install the temporary bolt to the rear door window regulator sub-assembly.
3. Temporarily install the window regulator.
4. Tighten the 4 bolts in the order shown in Fig 13 to install the rear door window regulator.
   Fig 13: Installing Rear Door Window Regulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf) 

5. Connect the connector.

1. Slide the rear door glass sub-assembly to install it.

Fig 14: Sliding Rear Door Glass Sub-Assembly

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1. Install the rear door quarter window glass to the rear door quarter weatherstrip.
2. Install the rear door quarter window glass together with the rear door quarter window glass weatherstrip in the direction indicated by the arrow.

Fig 15: Installing Rear Door Quarter Window Glass

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1. Insert the rear door window division bar from up above and install it with the 2 bolts and screw.

Fig 16: Inserting Rear Door Window Division Bar From Up Above

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1. Install the rear door glass run.

Fig 17: Installing Rear Door Glass Run

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1. Engage the 23 clips and install a new rear door weatherstrip.

Fig 18: Installing New Rear Door Weatherstrip

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1. Install the rear door check assembly with the bolt and the 2 nuts.
   Fig 19: Installing Rear Door Check Assembly With Bolt

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   Torque: Bolt 

   27 N*m (275 kgf*cm, 20 ft.*lbf) 

   Torque: Nut 

   8.0 N*m (82 kgf*cm, 71 in.*lbf) 

1. Install the rear door check cover.

Fig 20: Installing Rear Door Check Cover

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1. Apply butyl tape to the rear door panel.
2. Pass the rear door lock remote control cable, rear door inside locking cable and each connector through a new rear door service hole cover.
3. Install a new rear door service hole cover.
   NOTE: Securely install the rear door service hole cover avoiding wrinkles and air bubbles.
4. Connect the connector and clamp.

Fig 21: Connecting Connector & Clamp

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1. Install the door frame garnish with the 2 clips.

Fig 22: Installing Door Frame Garnish With Clips

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1. Engage the 5 clips to install the rear door trim cover.
2. Install the screw.

Fig 23: Installing Rear Door Trim Cover

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1. Engage the 3 claws to install the rear door inner glass weatherstrip.

Fig 24: Installing Rear Door Inner Glass Weatherstrip

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1. Install the rear door inside handle sub-assembly with the 5 screws.
   Fig 25: Installing Rear Door Inside Handle Sub-Assembly With Screws

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2. Install the bracket with the 3 screws.

1. Connect the rear door lock remote control cable and rear door inside locking cable to the rear inside handle.
2. Connect each connector.
   Fig 27: Connecting Rear Door Lock Remote Control Cable & Rear Door Inside Locking Cable

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3. Engage the rear door trim board with the 3 clips of the rear door inner glass weatherstrip.
   Fig 28: Engaging Rear Door Trim Board With Clips

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4. Engage the 8 clips to install the rear door trim board to the rear door panel.
5. Install the 2 screws.

Fig 29: Installing Rear Door Trim Board To Rear Door Panel

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1. Connect the connector.
2. Engage the 2 claws and 2 clips, and install the rear power window regulator switch assembly.

Fig 30: Installing Rear Power Window Regulator Switch Assembly

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1. Engage the 3 claws to install the rear door inside handle bezel plug.

Fig 31: Installing Rear Door Inside Handle Bezel Plug

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(See INITIALIZATION )