Rear 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:

Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.
A bolt without a torque specification is shown in the standard bolt chart (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

INSTALL CUSHION
INSTALL REAR DOOR LOCK CHILD PROTECTION COVER LH
INSTALL REAR DOOR WEATHERSTRIP LH
1. Attach the 18 clips to install the weatherstrip.
  
  Fig 1: Attaching Clips To Installing Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR CHECK ASSEMBLY LH
1. Apply MP grease to the sliding areas of the door check.
2. Install the door check to the door panel with the 2 bolts.
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) for bolt A
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 B
  
  Fig 2: Installing Door Check To Body Panel With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE FRONT PAD LH
1. Attach the 2 claws to install the pad.
  
  Fig 3: Attaching Claws To Installing Rear Door Outside Handle Front Pad
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE REAR PAD
1. Attach the 2 claws to install the pad.
INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
1. Install the outside handle frame release plate.
2. Attach the claw and clip to install the frame.
  
  Fig 5: Attaching Claw And Clip To Installing Rear Door Outside Handle Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the protector and screw.
  Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf)
  
  Fig 6: Installing Protector And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH
1. Install the handle by pushing and sliding it in the direction indicated by the arrows in the illustration.
  
  Fig 7: Installing Rear Door Outside Handle Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
1. Using a T30 "Torx" socket, install the cover with the screw.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 8: Installing Cover With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR LOCK ASSEMBLY LH
1. Apply MP grease to the sliding and rotating areas of the rear door lock.
2. Install the 2 cables as shown in the illustration.
  
  Fig 9: Installing Cables
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Attach the 4 claws to close the 2 covers.
  
  Fig 10: Attaching Claws To Close Covers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new door lock wire harness packing.
  NOTE:
  - When reinstalling the door lock, always use new packing.
    
    Fig 11: Installing Door Lock Wire Harness Packing
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - 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.
5. Connect the outside handle frame release plate into the door lock, and then set it to the door panel.
  NOTE: Make sure that the plate is securely engaged with the lock.
6. Apply adhesive to the threads of the 3 screws.
  Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
  
  Fig 12: Applying Adhesive To Threads Of Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a T30 "Torx" socket, install the door lock with the 3 screws.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
8. Connect the connector.
INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
1. Using a T25 "Torx" driver, install the motor with the 3 screws.
  Torque: 5.4 N*m (55 kgf*cm, 49 in.*lbf)
  
  Fig 13: Installing Power Window Regulator Motor With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH
1. Apply MP grease to the sliding and rotating areas of the window regulator.
  NOTE: Do not apply grease to the spring of the window regulator.
  
  Fig 14: Applying MP Grease To Sliding And Rotating Areas Of Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the regulator with the 4 bolts.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  NOTE: Be careful not to drop the window regulator as it may became damaged.
  
  Fig 15: Installing Regulator With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the connector.
INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH
1. Insert the door glass into the door panel as shown in the illustration. Then install the lower end of the door glass to the window regulator by sliding it in the direction of the arrow in the illustration.
  
  Fig 16: Inserting Door Glass Into Door Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR QUARTER WINDOW GLASS LH
1. Install the quarter window glass to the quarter window weatherstrip.
2. Install the quarter window glass (with weatherstrip) to the door panel.
  NOTE: Be careful not to damage the glass.
  
  Fig 17: Installing Quarter Window Glass To Quarter Window Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR WINDOW DIVISION BAR SUBASSEMBLY LH
1. Partially remove the rear door weatherstrip.
  HINT:
  
  It is not necessary to fully remove the rear door weatherstrip. Install the screw on the inner side of the rear door weatherstrip.
2. Install the division bar with the 2 bolts and screw.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 18: Installing Division Bar With Bolts And Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR GLASS RUN LH
INSTALL REAR DOOR BELT MOULDING ASSEMBLY LH (See appropriate step(s) under REMOVAL )
INSTALL REAR DOOR SERVICE HOLE COVER LH
1. Apply butyl tape to the door panel, then install a new rear door service hole cover as shown in Fig 19.
  NOTE:
  - 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 19: Installing Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect each connector.
INSTALL REAR DOOR INSIDE HANDLE SUBASSEMBLY LH
1. Connect the 2 cables to the inside handle.
  
  Fig 20: Connecting Cables To Inside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR NO. 1 SPEAKER ASSEMBLY (See appropriate step(s) under INSTALLATION )
INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH
1. Attach the 6 claws to install the weatherstrip inner.
2. Attach the 2 claws to install the inside handle.
  
  Fig 21: Attaching Claws To Installing Inside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Attach the 8 clips to install the trim board.
4. Install the 3 screws.
  
  Fig 22: Attaching Clips To Installing Trim Board
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Attach the 3 claws to install the door inside handle bezel plug.
  
  Fig 23: Attaching Claws To Installing Door Inside Handle Bezel Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Attach the 12 claws to install the door assist grip cover.
  
  Fig 24: Attaching Claws To Installing Door Assist Grip Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR ARMREST BASE UPPER PANEL LH
1. Attach the 2 claws and install the power window regulator switch to the panel.
2. Connect the switch connector.
  
  Fig 25: Installing Power Window Regulator Switch To Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Attach the clip and 5 claws to install the panel (with the switch).
  
  Fig 26: Attaching Clip And Claws To Installing Panel (With Switch)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL