REAR DOOR (for Hatchback without Power Window): Reassembly

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

INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
1. Apply MP grease to the sliding areas of the rear door outside handle frame.
2. Slide the outside handle frame to install it.
  
  Fig 1: Sliding Outside Handle Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE PAD FRONT
1. Engage the 2 claws and install the rear door outside pad front.
  
  Fig 2: Identifying Claws Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using "Torx" socket wrench T30, tighten the screw.
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
  
  Fig 3: Identifying "Torx" Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE PAD REAR
1. Engage the 2 claws and install the rear door outside pad rear.
  
  Fig 4: Identifying Claws Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY
1. Pushing the rear door outside handle in the direction of the arrow mark shown in Fig 5, install the rear door outside handle.
INSTALL REAR DOOR LOCK ASSEMBLY
NOTE:
- If reusing a door lock that has been removed, replace the packing in the connecting part with new.
- Make sure that no grease and dirt adheres to the packing surface in the connecting part.
1. Apply MP grease to the sliding and rotating areas of the front door lock.
  
  Fig 5: Pushing Rear Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the rear door lock remote control cable and rear door inside locking cable.
  
  Fig 6: Locating Rear Door Lock Remote Control Cable & Rear Door Inside Locking Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Engage the 7 claws and close the 2 covers.
4. Insert the door lock into the outside handle frame release plate, then set it onto the door panel.
5. Make sure that the outside handle frame link is securely engaged with the door lock.
6. Apply adhesive to the threads of the screws.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or the equivalent
  
  Fig 7: Locating Covers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using "Torx" socket wrench T30, install the rear door lock with the 3 screws.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  
  Fig 8: Locating "Torx" Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR OUTSIDE HANDLE COVER
1. Using "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)
INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY
1. Apply MP grease to the sliding and rotating areas of the rear door window regulator.
  NOTE: Do not apply grease to the window regulator spring.
2. Loosely screw bolt A onto the rear door window regulator.
  
  Fig 9: Locating Screw & Rear Door Outside Handle Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rear door window regulator into the door panel. Use bolt A to hang the rear door window regulator on the door panel.
  NOTE: Do not drop the window regulator as it may be damaged.
4. Install the rear door window regulator with the 2 bolts, and tighten bolt A.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 10: Identifying Bolts & Rear Door Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR GLASS SUB-ASSEMBLY
1. Install the rear door glass onto the rear door window regulator.
INSTALL REAR DOOR QUARTER WINDOW WEATHERSTRIP
1. Install the rear door quarter window glass onto the rear door quarter window weatherstrip.
  
  Fig 11: Identifying Rear Door Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Slide the rear door quarter window weatherstrip, in the direction indicated by the arrow, to install it.
  
  Fig 12: Sliding Rear Door Quarter Window Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY
1. Install the rear door window division bar with the 2 bolts and screw.
  Torque: 6.2 N*m (63 kgf*cm, 54 in.*lbf)
  
  Fig 13: Locating Bolts & Rear Door Window Division Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR GLASS RUN
1. Install the rear door glass run.
INSTALL REAR DOOR BELT MOLDING (See INSTALLATION )

Fig 14: Identifying Rear Door Glass Run
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR WEATHERSTRIP
1. Engage the 32 clips and install the rear door weatherstrip.
  
  Fig 15: Identifying Clips Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR CHECK ASSEMBLY
1. Apply MP grease to the sliding areas of the door check.
2. Install the rear door check onto the door panel with the 2 bolts.
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
3. Apply adhesive to the threads of the bolt.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or the equivalent
4. Install the rear door check onto the body panel with the bolt.
  Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)
  
  Fig 16: Identifying Bolts & Rear Door Check
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR DOOR SERVICE HOLE COVER

w/ Rear speaker:

Apply butyl tape to the door panel, then install the rear door service hole cover as shown in Fig 17 .

Adhesive:

Part No. 08850-00065, Butyl Tape Set or the equivalent

Specification

AREA DIMENSION TABLE

Area	Dimension
A	2.0 mm (0.079 in.) or more
B	6.0 mm (0.236 in.) or more

HINT:

When installing the service hole cover, pull the links and connectors out through the service hole.
There should be no wrinkles or folds after attaching the service hole cover.

Fig 17: Identifying Rear Door Service Hole Cover (With Rear Speaker)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
After attaching the service hole cover, check the quality of the seal.

w/o Rear speaker:

Apply butyl tape to the door panel, then install the rear door service hole cover as shown in Fig 18 .

Adhesive:

Part No. 08850-00065, Butyl Tape Set or the equivalent

Specification

AREA DIMENSION TABLE

Area	Dimension
A	2.0 mm (0.079 in.) or more
B	6.0 mm (0.236 in.) or more

HINT:

When installing the service hole cover, pull the links and connectors out through the service hole.
There should be no wrinkles or folds after attaching the service hole cover.
After attaching the service hole cover, check the quality of the seal.

Fig 18: Identifying Rear Door Service Hole Cover (Without Rear Speaker)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL REAR SPEAKER ASSEMBLY (w/ Rear Speaker) (See INSTALLATION )
INSTALL REAR DOOR GLASS WEATHERSTRIP INNER
1. Install the rear door glass weatherstrip inner onto the rear door trim board.
INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Engage the 6 claws and install the rear door inside handle.
  
  Fig 19: Identifying Claws Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY
1. Connect the rear door lock remote control cable and rear door inside locking cable.
2. Connect the connector.
  
  Fig 20: Identifying Rear Door Lock Remote Control Cable & Rear Door Inside Locking Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Engage the 7 clips and install the rear door trim board.
4. Tighten the 2 screws.
  
  Fig 21: Identifying Clips Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Engage the 3 claws and install the rear door armrest plug.
  
  Fig 22: Identifying Claws Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DOOR WINDOW REGULATOR HANDLE ASSEMBLY
1. Install the window regulator handle plate.
2. Open all the windows.
  
  Fig 23: Locating Window Regulator Handle Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the rear door window regulator handle with the clip at the angle shown in Fig 24 .
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Fig 24: Identifying Rear Door Window Regulator Handle Angle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002