Back Door: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

A bolt without a torque specification is shown in the standard bolt chart (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

INSTALL STOPPER
INSTALL CUSHION
1. Remove the 2 cushions.
INSTALL BACK DOOR SIDE FEMALE STOPPER
1. Install the stopper with the 2 bolts.
INSTALL BACK DOOR CHECK ASSEMBLY
1. Apply MP grease to the sliding areas of the door check.
2. Install the door check to the door panel with the 2 nuts.
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) for nut
3. Apply adhesive to the bolt.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
4. Install the door check to the body panel with the bolt.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) for bolt
  
  Fig 1: Installing Door Check To Door Panel With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK DOOR OUTSIDE HANDLE FRONT PAD
1. Attach the 2 claws to install the pad.
  
  Fig 2: Installing Back Door Outside Handle Front Pad
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK DOOR OUTSIDE HANDLE REAR PAD
1. Attach the 2 claws to install the pad.
INSTALL BACK DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
1. Install the front door lock open rod.
  
  Fig 3: Installing Back Door Outside Handle Rear Pad
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Attach the claw and clip to install the frame.
  
  Fig 4: Attaching Claw And Clip To Installing Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a T30 "Torx" socket, install the screw.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 5: Tightening T30 Torx Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK DOOR OUTSIDE HANDLE
1. Install the handle by pushing and sliding it in the direction indicated by the arrows in the illustration.
  
  Fig 6: Installing Back Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK DOOR OUTSIDE HANDLE COVER
1. Using a T30 "Torx" socket, install the cover with the screw.
  
  Fig 7: Installing Cover With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Install the hole plug.
INSTALL BACK DOOR LOCK ASSEMBLY
1. Apply MP grease to the sliding and rotating areas of the back door lock.
2. Install a new door lock wire harness packing (see Fig 8).
  NOTE:
  - When reinstalling the door lock, always use new packing.
  - Do not allow grease or dirt to contaminate the gap between the door panel and packing.
  - Old or damaged packing cannot effectively protect against water which can damage the door lock.
    
    Fig 8: Installing Door Lock Wire Harness Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the control rod into the door lock, and then set it to the door panel.
  
  Fig 9: Connecting Control Rod Into Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure that the rod is securely engaged with the lock.
4. Apply adhesive to the threads of the 3 screws.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
5. Using a T30 "Torx" socket, install the door lock with the 3 screws.
  
  Fig 10: Installing Door Lock With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
6. Connect the connector.
INSTALL STEREO COMPONENT REAR SPEAKER ASSEMBLY (See appropriate step(s) under INSTALLATION )
INSTALL BACK DOOR SERVICE HOLE COVER
1. Apply butyl tape to the door panel, then install a new back door service hole cover as shown in Fig 11.
  HINT:
  - When installing the service hole cover, pull out the links and connectors through the service hole cover.
  - There should be no wrinkles or folds after attaching the service hole cover.
  - After attaching the service hole cover, check the sealing quality.
  Fig 11: Installing Back Door Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect each connector.
INSTALL REAR WIPER MOTOR ASSEMBLY (See INSPECTION )
INSTALL SPARE WHEEL CARRIER BRACKET SUBASSEMBLY
1. Install the bracket with the 4 bolts.
  
  Fig 12: Installing Bracket With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 clips.
INSTALL UPPER BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY RH (See appropriate step(s) under INSTALLATION )
INSTALL LOWER BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY RH (See appropriate step(s) under INSTALLATION )
INSTALL UPPER BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY LH (See appropriate step(s) under INSTALLATION )
INSTALL LOWER BACK DOOR OUTSIDE GARNISH SUB-ASSEMBLY LH (See appropriate step(s) under INSTALLATION )
INSTALL REAR SPOILER (See appropriate step(s) under INSTALLATION )
INSTALL REAR WIPER ARM AND BLADE ASSEMBLY (See appropriate step(s) under INSPECTION )
INSTALL BACK DOOR TRIM BOARD
1. Install the back door trim pocket with the 5 screws.
2. Attach the 13 clips to install the trim board.
INSTALL BACK DOOR COURTESY LIGHT ASSEMBLY (See appropriate step(s) under INSTALLATION )
INSTALL BACK DOOR SIDE GARNISH LH
1. Attach the 2 claws and 2 clips to install the garnish.
  
  Fig 14: Attaching Clips To Installing Trim Board RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BACK DOOR SIDE GARNISH RH
HINT:

Use the same procedures described for the LH side.
INSTALL BACK DOOR CENTER GARNISH
1. Attach the 4 claws and 4 clips to install the garnish.
  
  Fig 15: Installing Back Door Center Garnish
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL