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Rear Door: Reassembly

  1. REPAIR INSTRUCTION  (See REMOVAL )
  2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE  (See INSTALLATION )
  3. INSTALL REAR DOOR OUTSIDE STRIPE  (See INSTALLATION )
  4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING  (See INSTALLATION )
  5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING  (See INSTALLATION )
  6. INSTALL REAR DOOR BELT MOULDING ASSEMBLY  (See INSTALLATION )
  7. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts on the rear door outside handle frame sub-assembly.
    2. Engage the claw to install the rear door outside handle frame sub-assembly.
    3. Using a "TORX" socket wrench (T30), install the rear door outside handle frame sub-assembly with the screw.
      Fig 1: Identifying Rear Door Outside Handle Frame Sub-Assembly Screw And Claw
      G04981783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the rear door rear outside handle pad.
      Fig 2: Identifying Rear Door Rear Outside Handle Pad Claws
      G04981778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the rear door front outside handle pad.
      Fig 3: Identifying Rear Door Front Outside Handle Pad Claws
      G04981777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.
      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 the release plate will be damaged.
    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 toward the front of the vehicle to install it.
      Fig 4: Identifying Rear Door Outside Handle Assembly
      G04981786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the claws to install the rear door outside handle cover.
      Fig 5: Identifying Rear Door Outside Handle Cover Claws
      G04981774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Screw
    G04981773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the rear door inside locking cable assembly.
      Fig 7: Identifying Rear Door Inside Locking Cable Assembly
      G04981772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 claws.
      Fig 8: Identifying Rear Door Inside Locking Cable Assembly Claws
      G04980492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the rear door lock remote control cable assembly.
      Fig 9: Identifying Rear Door Lock Remote Control Cable Assembly
      G04981791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw.
      Fig 10: Identifying Rear Door Lock Remote Control Cable Assembly Claw
      G04980490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR DOOR LOCK ASSEMBLY 
    NOTE:
    • When reusing the removed rear door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
    • Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion to the connection. This may result in a malfunction of the rear door lock assembly.
    1. Apply MP grease to the sliding parts of the rear door lock assembly.
    2. Install a new door lock wiring harness seal 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.
      Fig 11: Locating Rear Door Lock Assembly Screws
      G04980502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    6. Connect the connector.
  15. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    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: 5.4 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.

      Fig 12: Locating Power Window Regulator Motor Assembly Screws
      G04981767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts of 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 the illustration to install the rear door window regulator.

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

      Fig 13: Tightening Rear Door Window Regulator Sub-Assembly Bolts
      G04981795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the connector.
  17. INSTALL REAR DOOR FRAME GARNISH 
    1. Engage the clip and install a new rear door frame garnish.
      Fig 14: Identifying Rear Door Frame Garnish Clip
      G04981762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
      Fig 15: Identifying Rear Door Glass Run
      G04981797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. Slide the rear door glass sub-assembly to install it as shown in the illustration.
      Fig 16: Identifying Rear Door Glass Sub-Assembly
      G04981798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL REAR DOOR QUARTER WINDOW GLASS 
    1. Install the rear door quarter window glass to the rear door quarter window weatherstrip.
    2. 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.
      Fig 17: Locating Rear Door Quarter Window Glass
      G04981799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY 
    1. Insert the rear door lower window frame sub-assembly from above.
    2. Install the rear door glass run to the rear door lower window frame sub-assembly.
    3. Install the rear door lower window frame sub-assembly with the 2 bolts and screw.
      Fig 18: Identifying Rear Door Lower Window Frame Sub-Assembly Bolts And Screw
      G04981763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL REAR DOOR WEATHERSTRIP 
    1. Engage the 20 clips and install the rear door weatherstrip.
      Fig 19: Identifying Rear Door Weatherstrip Clips
      G04981760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL REAR DOOR CHECK ASSEMBLY (for TMC Made) 
    1. Install the rear door check assembly with the 3 bolts.
      Fig 20: Identifying Rear Door Check Assembly Bolts
      G04981802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      Bolt (A) 

      26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Bolt (B) 

      8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  24. INSTALL REAR DOOR CHECK ASSEMBLY (for TMMK Made) 
    1. Install the rear door check assembly with the bolt and 2 nuts.
      Fig 21: Identifying Rear Door Check Assembly Bolt And Nuts
      G04981759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      Bolt 

      26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Nut 

      8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  25. INSTALL REAR DOOR SERVICE HOLE COVER 
    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.
      Fig 22: Identifying Rear Door Service Hole Cover
      G04981804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 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.
  26. INSTALL REAR DOOR INSIDE PANEL REINFORCE 
    1. Install 4 new grommets.
    2. Install a new rear door inside panel reinforce with the 4 screws.
      Fig 23: Locating Rear Door Inside Panel Reinforce Screws And Grommets
      G04981756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 3 claws to install the rear door inner glass weatherstrip.
      Fig 24: Identifying Rear Door Inner Glass Weatherstrip Claws
      G04981806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL REAR DOOR ARMREST BASE PANEL UPPER 
    1. Engage the 4 claws.
    2. Install the rear door armrest base panel upper with the 7 screws.
      Fig 25: Locating Rear Door Armrest Base Panel Upper Screws And Claws
      G04981754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY 
    1. Engage the 2 claws and install the rear power window regulator switch assembly.
      Fig 26: Identifying Rear Power Window Regulator Switch Assembly Claws
      G04981752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Connect the rear door lock remote control cable and rear door inside locking cable to the rear inside handle.
      Fig 27: Identifying Door Lock Remote Control Cable And Rear Door Inside Locking Cable
      G04981809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 claws and install the rear door inside handle sub-assembly.
      Fig 28: Identifying Rear Door Inside Handle Sub-Assembly Claws
      G04981750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Engage the claw to install the No. 1 door scuff plate clamp.
      Fig 29: Identifying No. 1 Door Scuff Plate Clamp Claw
      G04981811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each connector.
    3. Engage the rear door trim board with the 4 clips of the rear door inner glass weatherstrip.
      Fig 30: Identifying Rear Door Trim Board Clips
      G04981749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 7 clips to install the rear door trim board to the rear door panel.
    5. Install the 3 screws.
      Fig 31: Identifying Rear Door Trim Board Clips And Screws
      G04981748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL DOOR ASSIST GRIP COVER 
    1. Engage the 6 claws and install the door assist grip cover.
      Fig 32: Identifying Door Assist Grip Cover Claws
      G04981814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws to install the rear door inside handle bezel plug.
      Fig 33: Identifying Rear Door Inside Handle Bezel Plug Claws
      G04981815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    (See INITIALIZATION )

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