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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 MOULDING 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.
  9. INSTALL REAR DOOR BELT MOULDING 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.
      Fig 1: Identifying Rear Door No. 2 Weatherstrip Clips And Claw
      G06114171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 claws 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.

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

      Fig 2: Installing Rear Door Outside Handle Frame Sub-Assembly
      G05422230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Installing 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: Loosening 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 On Rear Door Inside Locking Cable Assembly
    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.
  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.
    Fig 11: Identifying Claw On Rear Door Lock Remote Control Cable Assembly
    G05420290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  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.
    Fig 12: Installing Rear Door Lock Assembly With Screws
    G05420300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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: Locating 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 in the illustration.
  19. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door window regulator sub-assembly.
      Fig 14: Connecting Battery Lead To Terminal Of Rear Power Window Regulator Motor Assembly
      G05422242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

    5. Connect the connector.
    Fig 15: Locating Connector With Temporary Bolt
    G05422243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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
    G06114186Courtesy 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 in the illustration.
  23. INSTALL REAR DOOR QUARTER WINDOW GLASS 
    1. Install the rear door quarter window glass to the rear door quarter window weatherstrip.
      Fig 18: Installing Rear Door Quarter Window Glass To Rear Door Quarter Window Weatherstrip
      G05422246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  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.
      Fig 19: Installing Rear Door Quarter Window Glass With Rear Door Quarter Window Weatherstrip
      G05422247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 With Bolts And 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.

      Torque: Bolt 

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

      Nut 

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

  27. INSTALL REAR DOOR SERVICE HOLE COVER 
    1. Apply butyl tape to the rear door panel.
      Fig 23: Identifying Rear Door Check Assembly With Bolt And Nuts
      G05422202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
    4. Connect the connector.
  28. INSTALL REAR SPEAKER ASSEMBLY  (See INSTALLATION )
    Fig 24: Locating Connector With Reference Points On Rear Door Panel
    G05422252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Install the rear door inner glass weatherstrip.
    Fig 25: Identifying Rear Door Inner Glass Weatherstrip
    G06114195Courtesy 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 With Clips And Claw
    G06114196Courtesy 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: Connecting Rear Door Lock Remote Control Cable And Rear Door Inside Locking Cable To Rear Door Inside Handle Sub-Assembly
      G05422255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the rear door trim board with the 5 claws on the rear door inner glass weatherstrip.
    4. Engage the 9 clips and install the rear door trim board to the rear door panel.
      Fig 28: Identifying Claws On Rear Door Inner Glass Weatherstrip
      G05422197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 screws.
    6. Install the screw < A >.

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

      Fig 29: Identifying Rear Door Trim Board Sub-Assembly With Screws
      G06114199Courtesy 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.
  34. INSTALL REAR DOOR ARMREST UPPER BASE PANEL 
    1. Connect the connector.
      Fig 31: Identifying Claws Of Rear Power Window Regulator Switch Assembly
      G05421165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 And 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.
  36. CONNECT NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
    Fig 33: Identifying Claws On Rear Door Inside Handle Bezel Plug
    G05422185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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