Reassembly [04/2013 - 10/2016]: Procedure

PRECAUTION
NOTE:
After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

Refer to PRECAUTION [04/2013 - 08/2015] , or refer to PRECAUTION [08/2015 - 10/2016]
REPAIR INSTRUCTION
Refer to PROCEDURE - Step 1
INSTALL INNER UPPER BLACK OUT TAPE
Refer to PROCEDURE - Step 2
INSTALL FRONT INNER BLACK OUT TAPE
Refer to PROCEDURE - Step 3
INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY
Refer to PROCEDURE - Step 1
INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING
Refer to PROCEDURE - Step 2
INSTALL REAR DOOR BELT MOULDING ASSEMBLY
Refer to PROCEDURE - Step 8

INSTALL REAR DOOR PANEL CUSHION

Engage the claw to install a new rear door panel cushion.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

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

Engage the claw.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	Outside
*B	Inside

Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly with the screw.
Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf)

INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

Insert the front end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

If the release plate of the rear door outside handle frame sub-assembly is not pulled and held when installing the rear door outside handle assembly, the release plate of the rear door outside handle frame sub-assembly will interfere with the rear door outside handle assembly and the release plate will be damaged.

Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly, and slide the rear door outside handle assembly toward the front of the vehicle to install it.

Move the lever as shown in the illustration to lock the rear door outside handle assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR OUTSIDE HANDLE COVER

Engage the claw to temporary install the rear door outside handle cover.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw.
Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf)

INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

Install the rear door inside locking cable assembly as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Engage the 2 claws as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY

NOTE:

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

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

When reusing the rear door lock with motor assembly:

Install a new door lock wire harness seal to the rear door lock with motor assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Connect the rear door lock with motor assembly to the release plate, and set it to the rear door panel.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Release Plate

HINT:

Make sure that the release plate is securely connected to the rear door lock with motor assembly.

Using a T30 "TORX" socket wrench, install the rear door lock with motor assembly with the 3 screws.
Torque: 5.5 N.m (56 kgf/cm, 49 in.lbf)

INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTE:

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

Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws to the rear door window regulator sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

HINT:

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

INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY
1. Apply MP grease to the sliding parts of the rear door window regulator assembly.
2. Install the temporary bolt to the rear door window regulator assembly.
3. Temporarily install the rear door window regulator assembly.
  
  Fig 1: Rear Door Window Regulator Assembly Tightening Sequence [04/2013 - 10/2016]
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  *a Temporary Bolt
4. 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: 11 N.m (112 kgf/cm, 8 ft.lbf)
5. Connect the connector.

INSTALL REAR DOOR FRAME GARNISH

Engage the 3 claws to install the rear door frame garnish.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR GLASS CHANNEL FILLER

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

Install the rear door glass channel filler to the rear door glass assembly at position shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	Front Side
*B	Rear Side
*a	Edge of curved surface

STANDARD DIMENSION

Area	Measurement
A	25.8 mm (1.0157 in.)
B	15.6 mm (0.6142 in.)

INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY

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

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*A	Front Side
*B	Rear Side
*a	Edge of curved surface

NOTE:

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

STANDARD DIMENSION

Area	Measurement
A	25.8 mm (1.0157 in.)
B	15.6 mm (0.6142 in.)

INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR QUARTER WINDOW GLASS

Install the rear door quarter window glass to the rear door quarter window weatherstrip.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the rear door quarter window glass together with the rear door quarter window weatherstrip as shown in the illustration.

INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR GLASS RUN

Install the rear door glass run.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR WEATHERSTRIP

Clean the rear door panel sub-assembly.
Remove the release paper from a new rear door weatherstrip.
HINT:

After removing the release paper, keep the exposed adhesive free from foreign matter.

Engage the 23 clips to install the rear door weatherstrip.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR CHECK ASSEMBLY

Apply MP grease to the sliding parts of the rear door check assembly.
Apply adhesive to the threads of the bolt.
Adhesive

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Nut

Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf)

Bolt

Torque: 27 N.m (275 kgf/cm, 20 ft.lbf)

INSTALL REAR DOOR DUST PROOF SEAL

Engage the 2 claws to install a new rear door dust proof seal.

INSTALL REAR DOOR SERVICE HOLE COVER

Apply new butyl tape to the rear door panel.

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

*a	Reference Point

Attach the rear door service hole cover according to the reference points on the rear door panel.
NOTE:
Securely install the rear door service hole cover preventing wrinkles and air bubbles.
Engage the clamp.

INSTALL REAR SPEAKER ASSEMBLY
Refer to PROCEDURE - Step 1
INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 15 Speakers)
Refer to PROCEDURE - Step 2

INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

Install the rear door inner glass weatherstrip.

INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

Engage the 3 guides.

Install the rear door inside handle sub-assembly with the 6 screws.

INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

for 15 Speakers:
1. Connect the connector.

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

*1	Rear Door Inside Locking Cable Assembly
*2	Rear Door Lock Remote Control Cable Assembly

Engage the 3 claws and reference boss as shown in the illustration to temporarily install the rear door trim board sub-assembly.

*a	Reference Boss

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

Install the 3 screws.
HINT:

If protective tape has been applied, remove it.

INSTALL REAR DOOR NO. 1 STIFFENER CUSHION

Install the rear door No. 1 stiffener cushion with the screw.

INSTALL REAR DOOR NO. 3 ARMREST COVER

Engage the 2 guides.

Engage the 2 claws, and install the rear door No. 3 armrest cover.

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

Connect the connector.

Engage the 2 clips, 5 claws and 6 guides, and install the rear power window regulator switch assembly with rear door armrest base panel.

INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

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

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Refer to INITIALIZATION [04/2013 - 06/2014] , or refer to INITIALIZATION [06/2014 - 08/2015] , or refer to INITIALIZATION [08/2015 - 10/2016]
INITIALIZE POWER WINDOW CONTROL SYSTEM
Refer to INITIALIZATION [04/2013 - ]
INSPECT POWER WINDOW OPERATION
Refer to OPERATION CHECK [04/2013 - ]