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Rear Door: Reassembly

  1. INSTALL REAR DOOR BELT MOLDING ASSEMBLY 
  2. INSTALL REAR DOOR WEATHERSTRIP 
  3. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Install the rear door check assembly with the 3 bolts.

      Torque: door side 

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

      Torque: body side 

      27 N*m (275 kgf*cm, 20 ft.*lbf) 

  4. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply body grease to the sliding parts on the rear door outside handle frame sub-assembly.
      Fig 1: Identifying Rear Door Check Assembly Bolts
      G05244208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 claws.
      Fig 2: Identifying Claws Of Rear Door Outside Handle Frame Sub-Assembly
      G05244207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a "Torx" socket wrench (T30), install the rear door outside handle frame sub-assembly.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 3: Locating Rear Door Outside Handle Frame Sub-Assembly Screw
      G05244206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL REAR DOOR OUTSIDE HANDLE PAD REAR 
  6. INSTALL REAR DOOR OUTSIDE HANDLE PAD 
  7. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY 
  8. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the 2 claws.
      Fig 4: Identifying Claws Of Rear Door Outside Handle Cover
      G05244201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a "Torx" socket wrench (T30), install the rear door outside handle cover with the screw.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 5: Installing Rear Door Outside Handle Cover
      G05244200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR DOOR LOCK ASSEMBLY 
    NOTE:
    • When reusing the removed rear door lock assembly, replace the door lock wire harness sealing on the connector with a new one.
    • Do not adhere the grease or dust to the door lock wire harness sealing surface of the connector.
    • Reusing the door lock wire harness sealing and/ or using damaged door lock wire harness sealing may cause water intrusion to the connection, and result in a malfunction on the rear door lock assembly.
    1. Apply body grease to the sliding parts on the rear door lock assembly.
    2. Insert the rear door lock assembly to the rear door outside handle release plate, and set to rear door panel.
      3. Fig 6: Identifying Rear Door Lock Assembly
      G05244218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.
    4. Using a "Torx" socket wrench (T30), install the rear door lock assembly with the 3 screws.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    5. Install the bolt.

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

    6. Connect the connector.
  10. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR 
    NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.
    1. Using a "Torx" driver (T25), install the power window regulator motor assembly with the 3 screws.

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

      HINT:

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

      Fig 7: Locating Power Window Regulator Motor Assembly Screws
      G05244198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Apply body 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. Fig 8: Identifying Temporary Bolt Of Rear Door Window Regulator Sub-Assembly
      G05244197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 4 bolts and install the rear door window regulator sub-assembly.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

    4. Connect the connector.
  12. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
  13. INSTALL REAR DOOR QUARTER WINDOW GLASS 
  14. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
  15. INSTALL REAR DOOR GLASS RUN 
  16. INSTALL REAR DOOR SERVICE HOLE COVER 
    1. Apply butyl tape to the rear door panel, as shown in the illustration.
      2. Fig 9: Identifying Butyl Tape To Rear Door Panel
      G05244221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear door service hole cover.
  17. INSTALL REAR SPEAKER  (See REMOVAL )
  18. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Connect the 2 cables.
    2. Install the rear door inside handle sub-assembly with the bolt and the 2 claws.

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

      Fig 10: Identifying Claws Of Rear Door Inside Handle Sub-Assembly
      G05244157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
  20. INSTALL DOOR PULL HANDLE 
  21. INSTALL REAR DOOR INSIDE HANDLE BEZEL 
    1. Install the rear door inside handle bezel with the screw and the 3 claws.

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

  22. POWER WINDOW CONTROL SYSTEM INITIALIZATION 

    (See INITIALIZATION )

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