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Rear Door: Reassembly

  1. REPAIR INSTRUCTION  (See INSTALLATION )
  2. INSTALL INNER REAR BLACK OUT REAR DOOR TAPE  (See INSTALLATION )
  3. INSTALL INNER FRONT BLACK OUT REAR DOOR TAPE  (See INSTALLATION )
  4. INSTALL INNER UPPER BLACK OUT REAR DOOR TAPE  (See INSTALLATION )
  5. INSTALL NO. 2 BLACK OUT TAPE  (See INSTALLATION )
  6. INSTALL NO. 3 BLACK OUT TAPE  (See INSTALLATION )
  7. INSTALL REAR DOOR OUTSIDE MOLDING SUB-ASSEMBLY  (See INSTALLATION )
  8. INSTALL REAR DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 11 clips and claw, and install the rear door No. 2 weatherstrip.
      Fig 1: Identifying Rear Door No. 2 Weatherstrip Clips
      G05422225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR DOOR BELT MOLDING ASSEMBLY  (See INSTALLATION )
  10. 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 2 claws to install the rear door outside handle frame sub-assembly.
      Fig 2: Identifying Rear Door Outside Handle Frame Sub-Assembly Claws
      G05422230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a "TORX" socket wrench (T30), install the rear door outside handle frame sub-assembly with the screw.

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

  11. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the rear door rear outside handle pad.
      Fig 3: Identifying Rear Door Rear Outside Handle Pad & Claws
      G05422125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the rear door front outside handle pad.
      Fig 4: Identifying Rear Door Front Outside Handle Pad & Claws
      G05422124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 may 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 5: Identifying Rear Door Outside Handle Assembly
      G05422233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the claw to install the rear door outside handle cover.
      Fig 6: Identifying Rear Door Outside Handle Cover & Claw
      G05422219Courtesy 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 7: Identifying Rear Door Outside Handle Cover Screw
      G05422218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the rear door inside locking cable assembly.
      Fig 8: Identifying Rear Door Inside Locking Cable Assembly
      G05420293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 claws.
      Fig 9: Identifying Claws
      G05420292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the rear door lock remote control cable assembly.
      Fig 10: Identifying Rear Door Lock Remote Control Cable Assembly
      G05420291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw.
      Fig 11: Identifying Claw Location
      G05420290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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.
    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) 

      Fig 12: Identifying Rear Door Lock Assembly Screws
      G05420300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    NOTE: The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.
    1. Using a "TORX" driver (T25), install the rear power window regulator motor assembly with the 3 screws.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      HINT:

      A new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

      Fig 13: Identifying Rear Power Window Regulator Motor Assembly Screws
      G05421174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the positive (+) lead of the battery to terminal 1, and the negative (-) lead to terminal 2 of the rear power window regulator motor assembly to move the lift arm to the position shown below.
      Fig 14: Moving Lift Arm
      G05422242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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 below to install the rear door window regulator.

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

      Fig 15: Identifying Rear Door Window Regulator Bolts
      G05422243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the connector.
  20. INSTALL REAR DOOR FRAME GARNISH 
    1. Engage a new clip and install the rear door frame garnish.
      Fig 16: Identifying Rear Door Frame Garnish Clip
      G05422205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
      Fig 17: Identifying Rear Door Glass Run
      G05422204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. Slide the rear door glass sub-assembly to install it as shown below.
      Fig 18: Identifying Rear Door Glass Sub-Assembly
      G05422246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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 shown below.
      Fig 19: Identifying Rear Door Quarter Window Glass & Weatherstrip
      G05422247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Insert the rear door window division bar 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 window division bar sub-assembly with the 2 bolts and screw.
      Fig 20: Identifying Rear Door Window Division Bar Sub-Assembly Bolts & Screw
      G05422207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the rear door vent seal.
      Fig 21: Identifying Rear Door Vent Seal
      G05422206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL REAR DOOR WEATHERSTRIP 
    1. Engage the 19 clips and install the rear door weatherstrip.
      Fig 22: Identifying Rear Door Weatherstrip Clips
      G05422203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Install the rear door check assembly with the bolt and 2 nuts.

      Bolt 

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

      Nut 

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

      Fig 23: Identifying Rear Door Check Assembly Bolt & Nuts
      G05422202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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.
    3. Attach the rear door service hole cover according to the reference points on the rear door panel.
      NOTE: Securely install the rear door service hole cover avoiding wrinkles and air bubbles.
      Fig 24: Identifying Rear Door Service Hole Cover
      G05422252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector.
  28. INSTALL REAR SPEAKER ASSEMBLY  (See INSTALLATION )
  29. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Install the rear door inner glass weatherstrip.
      Fig 25: Identifying Rear Door Inner Glass Weatherstrip
      G05422200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 2 claws.
    2. Install the 2 screws and install the rear door inside handle sub-assembly.
      Fig 26: Identifying Rear Door Inside Handle Sub-Assembly Claws & Screws
      G05422199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the rear door lock remote control cable and rear door inside locking cable to the rear door inside handle sub-assembly.
    2. Engage the 2 clamps.
      Fig 27: Identifying Rear Door Lock Remote Control Cable & Rear Door Inside Locking Cable
      G05422255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the rear door trim board with the 5 claws on the rear door inner glass weatherstrip.
      Fig 28: Identifying Rear Door Trim Board Sub-Assembly Claws
      G05422197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 9 clips and install the rear door trim board to the rear door panel.
    5. Install the 2 screws < B >.
    6. Install the screw < A >.

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

      Fig 29: Identifying Screws
      G05422257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL DOOR ASSIST GRIP COVER 
    1. Engage the 4 claws and install the door assist grip cover.
      Fig 30: Identifying Door Assist Grip Cover Claws
      G05422258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY 
    1. Engage the 2 claws and install the rear power window regulator switch assembly.
      Fig 31: Identifying Rear Power Window Regulator Switch Assembly Claws
      G05421165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL REAR DOOR ARMREST UPPER BASE PANEL 
    1. Connect the connector.
    2. Engage the 6 claws and 2 clips and install the rear door armrest upper base panel.
      Fig 32: Identifying Rear Door Armrest Upper Base Panel Claws & Clips
      G05422260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. 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
      G05422185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. CONNECT NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
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