Reassembly [09/2014 - ]

HINT: 

• Use the same procedure for the RH side and LH side.
• The following procedure is for the LH side.

1. REPAIR INSTRUCTION  . Refer to INSTALLATION [09/2014 - ] - Step 2
2. INSTALL NO. 2 BLACK OUT TAPE  . Refer to INSTALLATION [09/2014 - ] - Step 4
3. INSTALL REAR DOOR LOWER OUTSIDE STRIPE  . Refer to INSTALLATION [09/2014 - ] - Step 2
4. INSTALL REAR DOOR OUTSIDE STRIPE  . Refer to INSTALLATION [09/2014 - ] - Step 3
5. INSTALL REAR DOOR REAR WINDOW FRAME MOLDING  . Refer to INSTALLATION [09/2014 - ] - Step 1
6. INSTALL REAR DOOR UPPER WINDOW FRAME MOLDING  . Refer to INSTALLATION [09/2014 - ] - Step 2
7. INSTALL REAR DOOR FRONT WINDOW FRAME MOLDING  . Refer to INSTALLATION [09/2014 - ] - Step 3
8. INSTALL REAR DOOR BELT MOLDING ASSEMBLY  . Refer to INSTALLATION [09/2014 - ] - Step 1
9. INSTALL REAR DOOR PANEL CUSHION 
   1. Engage the 2 claws to install 2 new rear door panel cushions.
      Fig 1: Identifying Rear Door Panel Cushions

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL REAR DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 5 clips to install the rear door No. 2 weatherstrip.
       Fig 2: Identifying Rear Door No. 2 Weatherstrip Clips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly.
    2. Engage the claw.
       Fig 3: Identifying Rear Door Outside Handle Frame Screw And Door Handle Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	Door Handle Nut
       *a	Outside
       *b	Inside

    3. Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly with the screw and door handle nut.

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

12. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the rear door rear outside handle pad.
       Fig 4: Identifying Rear Door Rear Outside Handle Pad Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the rear door front outside handle pad.
       Fig 5: Identifying Rear Door Front Outside Handle Pad Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. 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 sub-assembly.
       Fig 6: Installing Rear Door Outside Handle

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: If the release plate of the rear door outside handle frame sub-assembly is not pulled and held when installing the rear door outside handle assembly, it will interfere with the rear door outside handle assembly and will be damaged.
    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame sub-assembly, then slide the rear door outside handle assembly toward the front of the vehicle to install it.
15. INSTALL REAR DOOR OUTSIDE HANDLE COVER 
    1. Engage the claw.
       Fig 7: Identifying Rear Door Outside Handle Cover Claw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw.

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

16. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the rear door inside locking cable assembly.
       Fig 8: Installing Rear Door Inside Locking Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 claws as shown in the illustration.
       Fig 9: Identifying Rear Door Inside Locking Cable Cover Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. 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

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw as shown in the illustration.
       Fig 11: Identifying Claw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. INSTALL REAR DOOR LOCK WITH MOTOR ASSEMBLY 
    NOTE:

    • When reusing a removed rear door lock with motor assembly, replace the door lock wiring harness seal with a new one.
    • Do not allow grease or dust to adhere to the door lock wiring harness seal installation surface.
    • Reusing a door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water ingress. This may result in a malfunction of the rear door lock with motor assembly.
    1. Apply MP grease to the sliding parts of the rear door lock with motor assembly.
    2. When reusing the rear door lock with motor assembly.
       1. Install a new door lock wiring harness seal to the rear door lock with motor assembly.
          Fig 12: Identifying Door Lock Wiring Harness Seal

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the rear door lock with motor assembly to the release plate of the rear door outside handle frame sub-assembly, and set it to the rear door panel.
       Fig 13: Identifying Release Plate

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *a	Release Plate

       HINT: 

       Make sure that the release plate of the rear door outside handle frame sub-assembly is securely connected to the rear door lock with motor assembly.

    4. Using a T30 "TORX" socket wrench, install the rear door lock with motor assembly with the 3 screws.

       Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

19. 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 T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.
       Fig 14: Identifying Rear Power Window Regulator Motor Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

       HINT: 

       When replacing a rear power window regulator motor assembly, a new rear power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are installed.

20. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door window regulator assembly.
    2. Temporarily install the temporary bolt to the rear door window regulator assembly.
    3. Temporarily install the rear door window regulator assembly with the 3 bolts.
       Fig 15: Identifying Rear Door Window Regulator Assembly Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *a	Temporary Bolt

    4. Tighten the temporary bolt and 3 bolts to install the rear door window regulator assembly.

       HINT: 

       Tighten the bolts in the order shown in the illustration.

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

21. INSTALL REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY 
    1. Engage the guide.
       Fig 16: Identifying Rear Door Inside Panel Reinforce Sub-Assembly Screws And Guide

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new rear door inside panel reinforce sub-assembly with the 4 screws.
22. INSTALL REAR DOOR FRAME GARNISH 
    1. Engage the clip to install a new rear door frame garnish.
       Fig 17: Identifying Rear Door Frame Garnish Clip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL REAR DOOR GLASS SUB-ASSEMBLY 
    1. Slide the rear door glass sub-assembly to install it as shown in the illustration.
       Fig 18: Identifying Rear Door Glass Sub-Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE: Do not damage the rear door glass sub-assembly.
24. 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 as shown in the illustration.
       Fig 19: Installing Rear Door Quarter Window Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY 
    1. Install the rear door lower window frame sub-assembly with the screw and 2 bolts.
       Fig 20: Identifying Bolts, Screw And Rear Door Lower Window Frame Sub-Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL REAR DOOR GLASS RUN 
    1. Install the rear door glass run.
       Fig 21: Identifying Rear Door Glass Run

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL REAR DOOR WEATHERSTRIP 
    1. Engage the 20 clips to install the rear door weatherstrip.
       Fig 22: Identifying Clips And Rear Door Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL REAR DOOR CHECK ASSEMBLY 
    1. Apply MP grease to the sliding parts of the rear door check assembly.
    2. Clean the bolt hole on the vehicle body.
    3. Clean the bolt threads of the bolt.
    4. Apply adhesive to the threads of the bolt.

       Adhesive

       Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the rear door check assembly with the 2 nuts and bolt.
       Fig 23: Identifying Rear Door Check Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Bolt 

       Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

       Nut 

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

29. INSTALL REAR DOOR SERVICE HOLE COVER 
    1. Apply new butyl tape to the rear door panel.
    2. Pass the rear door lock remote control cable assembly, rear door inside locking cable assembly and each connector through a new rear door service hole cover.
       Fig 24: Identifying Reference Point

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *a	Reference Point

    3. Install the new rear door service hole cover according to the reference points on the rear door panel.
       NOTE: Securely install the rear door service hole cover preventing wrinkles and air bubbles.
    4. Connect the connector.
30. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Install the rear door inner glass weatherstrip.
       Fig 25: Identifying Rear Door Inner Glass Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the guide and 2 claws to install the rear door inside handle sub-assembly to the rear door trim board sub-assembly.
       Fig 26: Identifying Rear Door Inside Handle Sub-Assembly Claws And Guides

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Install the No. 1 door scuff plate clamp as shown in the illustration.
       Fig 27: Identifying No. 1 Door Scuff Plate Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.
       Fig 28: Identifying Rear Door Inside Locking Cable Assembly And Rear Door Lock Remote Control Cable Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	Rear Door Inside Locking Cable Assembly
       *2	Rear Door Lock Remote Control Cable Assembly

    3. Engage the 4 claws and reference boss as shown in the illustration.
       Fig 29: Identifying Claws And Reference Boss

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *a	Reference Boss

    4. Engage the 8 clips to install the rear door trim board sub-assembly.
       Fig 30: Identifying Clips And Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 3 screws.
    6. Remove protective tape.
33. INSTALL REAR ARMREST ASSEMBLY 
    1. Engage the 2 guides, 3 clips and 7 claws to install the rear armrest assembly.
       Fig 31: Identifying Rear Armrest Clips, Claws And Guides

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL 
    1. Connect the connector.
    2. Engage the 3 guides, 2 clips and 5 claws to install the rear power window regulator switch assembly with rear door armrest base panel.
       Fig 32: Identifying Guides, Clips And Claws

       Courtesy 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

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION [09/2014 - ]
37. INSPECT POWER WINDOW OPERATION 

    Refer to OPERATION CHECK [09/2014 - ]