Reassembly [12/2012 - 08/2016]: Procedure

1. Install a new rear door panel cushion.

Refer to PROCEDURE - Step 1 [12/2012 - 10/2015] , or refer to PROCEDURE - Step 1 [10/2015 - ]

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

1. Attach the claw to install the rear door frame garnish LH.

1. Attach the 19 clips to install the rear door weatherstrip LH.

1. Apply MP grease to the sliding area of the rear door check assembly LH.
2. When reusing a bolt labeled B:
   1. Clean the threads of the bolt with non-residue solvent.
   2. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

3. Install the door check to the door panel with the 2 bolts labeled A.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Bolt A
   *2	Bolt B

   Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

4. Install the rear door check assembly with the 2 bolts labeled B.

   Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

1. Apply MP grease to the sliding area of the rear door outside handle frame sub-assembly LH.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	Outside
   *B	Inside

2. Attach the claw to install the rear door outside handle frame sub-assembly LH.
3. Using a T30 "TORX" socket wrench, tighten the screw.

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

1. Attach the 2 claws to install the rear door front outside handle pad.

1. Attach the 2 claws to install the rear door rear outside handle pad.

1. Apply MP grease to the sliding area of the rear door outside handle assembly LH.
2. Install the rear door outside handle assembly LH by moving it in the direction indicated by the arrow shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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 will be damaged.

1. Using a T30 "TORX" socket wrench, tighten the screw to install the rear door outside handle cover LH.

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

1. Install the rear door inside locking cable assembly LH.
2. Attach the 3 claws to close the cover.

1. Install the rear door lock remote control cable assembly LH.
2. Attach the claw to close the cover.

Refer to PROCEDURE - Step 3

1. Install the rear door lock child protection cover LH.

Refer to PROCEDURE - Step 1

HINT: 

When installing the rear door stiffener cushion LH, heat the rear door panel using a heat light.

Standard

1. Clean the rear door panel surface.
   1. Using a heat light, heat the rear door panel surface.
   2. Remove the double-sided tape from the rear door panel.
   3. Wipe off any tape adhesive residue with cleaner.
2. Install a new rear door stiffener cushion LH.
   1. Using a heat light, heat the rear door stiffener cushion LH.
   2. Remove the peeling paper from the face of the rear door stiffener cushion LH.

      HINT: 

      After removing the peeling paper, keep the exposed adhesive free from foreign matter.

   3. Install the rear door stiffener cushion LH with the 2 bolts.

      HINT: 

      Press the rear door stiffener cushion LH firmly to install it.

      Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 

Refer to PROCEDURE - Step 1

1. Apply MP grease to the sliding and rotating areas of the rear door window regulator.
2. Temporarily install the temporary bolt to the rear door window regulator.
3. Install the rear door window regulator with the 3 bolts, and then tighten the temporary bolt.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Temporary Bolt

   HINT: 

   Tighten the bolts in the order shown in the illustration.

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

   NOTE:

   Be careful not to drop the rear door window regulator as it may become damaged.

4. Connect the connector.

1. Install a new rear door glass channel filler to the rear door glass as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	Front Side
   *B	Rear Side
   *a	Edge of curved surface

   Standard

   Area	Dimension
   A	42 mm (1.65 in.)
   B	12 mm (0.472 in.)

1. Apply soapy water to the inside of the rear door glass channel sub-assembly LH.
2. Using a plastic-faced hammer, tap the rear door glass channel sub-assembly LH onto the rear door glass sub-assembly LH to install the rear door glass channel sub-assembly LH as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *A	Front Side
   *B	Rear Side
   *a	Edge of curved surface

   Standard

   Area	Dimension
   A	42 mm (1.65 in.)
   B	12 mm (0.472 in.)

   NOTE:

   To prevent damaging the rear door glass sub-assembly, be careful not to strike the channel with too much force.

1. Install the front side of the rear door glass run.

1. Temporarily install the rear power window regulator switch assembly with rear door armrest base panel.
2. Connect the cable to the negative (-) battery terminal.
3. Operate the rear door window regulator so that the rear door glass can be installed.
4. Disconnect the cable from the negative (-) battery terminal.
   NOTE:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

   Refer to INITIALIZATION [12/2012 - 10/2015] , or refer to INITIALIZATION [10/2015 - 08/2016]

5. Remove the rear power window regulator switch assembly with rear door armrest base panel.
6. Apply MP grease to the sliding area of the rear door glass channel as shown in the illustration.

   Standard

   Area	Specified Condition
   A	157 mm (6.18 in.)
   B	25 mm (0.984 in.)
   C	5 mm (0.197 in.)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   MP Grease

7. Slide the rear door glass sub-assembly LH to install it as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Do not damage the door glass.

1. Install the rear door quarter window weatherstrip LH to the rear door quarter window glass LH.

1. Install the rear door quarter window glass LH.

1. Align the rear door glass run with the rear door window division bar.
2. Insert the rear door window division bar together with the rear door glass run into the rear door panel.
3. Install the screw and 2 bolts.

   Screws 

   Torque: 3.6 N*m (37 kgf*cm, 32 in.*lbf) 

   Bolt 

   Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 

4. Finish installing the upper side of the rear door glass run.

1. Apply new butyl tape to the rear door panel.
2. Pass the rear door inside locking cable, rear door lock remote control cable and wire harness through a new rear door service hole cover, and then attach the rear door service hole cover using the reference points on the rear door panel.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Reference Point

   NOTE:

   • Securely install the rear door service hole cover to prevent wrinkles and air bubbles.
   • There should be no wrinkles or folds after installing the rear door service hole cover.
   • After installing the rear door service hole cover, check the seal quality.

Refer to PROCEDURE - Step 1

1. Install the rear door inner glass weatherstrip LH to the rear door trim board sub-assembly LH and fold down the 6 claws in the directions indicated by the arrows in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Attach the 2 claws and guide to install the rear door inside handle sub-assembly LH.

1. Connect the rear door lock remote control cable LH and rear door inside locking cable LH.
2. Engage the rear door lock remote control cable assembly LH and rear door inside locking cable assembly LH to the 2 clamps.
3. Attach the 8 clips to install the rear door trim board sub-assembly LH.
4. Install the 3 screws.

1. Attach the 3 claws to install the rear door inside handle bezel plug LH.

1. Attach the 5 claws, 2 clips and guide to install the door assist grip cover LH.

Refer to PROCEDURE - Step 1

1. Connect the connector.
2. Attach the 5 claws, 2 guides and 2 clips to install the rear power window regulator switch assembly with rear door armrest base panel.

Refer to OPERATION CHECK [12/2012 - 10/2015] , or refer to OPERATION CHECK [10/2015 - ]

Refer to OPERATION CHECK [12/2012 - ]