Reassembly

DOOR / HATCH: REAR DOOR: REASSEMBLY

1. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

2. INSTALL REAR DOOR REAR WINDOW FRAME MOULDING

3. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING SUB-ASSEMBLY

4. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

5. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY Installation

6. INSTALL NO. 2 ACCESS PANEL WEATHERSTRIP

HINT
When installing the No. 2 access panel weatherstrip, heat the rear door panel protector and No. 2 access panel weatherstrip using a heat light.

Heating Temperature

NOTICE:
Do not heat the rear door panel protector or No. 2 access panel weatherstrip excessively.

(a) Using a heat light, heat the rear door panel protector surface.

(b) Remove the double-sided tape from the rear door panel protector.

(c) Wipe off any tape adhesive residue with cleaner.

(d) If reusing the No. 2 access panel weatherstrip:

(1) Using a heat light, heat the No. 2 access panel weatherstrip.

(2) Clean the No. 2 access panel weatherstrip.

(3) Remove the double-sided tape from the No. 2 access panel weatherstrip.

(4) Wipe off any tape adhesive residue with cleaner.

(5) Apply new double-sided tape to the No. 2 access panel weatherstrip as shown in the illustration.

Text in Illustration

(e) Engage the 5 clips to install the No. 2 access panel weatherstrip.

Text in Illustration

7. INSTALL REAR DOOR PANEL PROTECTOR

HINT
When installing the rear door panel protector, heat the vehicle body and rear door panel protector using a heat light.

Heating Temperature

NOTICE:
Do not heat the vehicle body or rear door panel protector excessively.

(a) Using a heat light, heat the vehicle body surface.

(b) Remove the double-sided tape from the vehicle body.

(c) Wipe off any tape adhesive residue with cleaner.

(d) If reusing the rear door panel protector:

(1) Using a heat light, heat the rear door panel protector.

(2) Clean the rear door panel protector.

(3) Remove the double-sided tape from the rear door panel protector.

(4) Wipe off any tape adhesive residue with cleaner.

(5) Apply new double-sided tape to the rear door panel protector as shown in the illustration.

(e) Engage the 11 clips and guide to install the rear door panel protector as shown in the illustration.

Text in Illustration

8. INSTALL REAR DOOR LOWER OUTSIDE MOULDING Installation

9. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly.

(b) Engage the door handle nut and claw.

(c) Using a T30 "TORX" socket wrench, install the rear door outside handle frame sub-assembly with the screw.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

10. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 2 claws and install the rear door rear outside handle pad.

11. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the 3 claws to install the rear door front outside handle pad.

12. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

(a) Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.

NOTICE:
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.

(b) 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.

(c) Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

13. INSTALL REAR DOOR OUTSIDE HANDLE COVER

(a) Engage the claw and install the rear door outside handle cover.

(b) Using a T30 "TORX" socket wrench, install the rear door outside handle cover with the screw.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

14. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Install the rear door inside locking cable assembly.

(b) Engage the 3 claws.

15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

(a) Install the rear door lock remote control cable assembly.

(b) Engage the claw.

16. INSTALL REAR DOOR LOCK ASSEMBLY

NOTICE:
* 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. This may result in a malfunction of the rear door lock assembly.

(a) Apply MP grease to the sliding parts of the rear door lock assembly.

(b) Install a new door lock wiring harness seal to the rear door lock assembly.

(d) Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.

(e) Using a T30 "TORX" socket wrench, install the rear door lock assembly with the 3 screws.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

17. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTICE:
The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.

(a) Using a T25 "TORX" socket wrench, install the rear power window regulator motor assembly with the 3 screws.

Torque : 5.4 Nm (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.

18. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY

(a) Apply MP grease to the sliding parts of the rear door window regulator assembly.

(b) Install the temporary bolt to the rear door window regulator assembly.

(c) Temporarily install the rear door window regulator assembly.

Text in Illustration

(d) Tighten the temporary bolt and 5 bolts to install the rear door window regulator assembly.

HINT
Tighten the bolts in the order shown in the illustration.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

19. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

(a) Connect the cable to the negative (-) battery terminal and the rear power window regulator motor connector.

(b) Connect the power window regulator switch assembly and move the rear door glass sub-assembly so that the door glass bolts can be seen.

(1) w/ Navigation System for HDD:

NOTICE:
After the power switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

(c) Disconnect the power window regulator switch assembly and rear power window regulator motor connector.

(d) Disconnect the cable from the negative (-) battery terminal.

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system Service and Repair.

(e) Insert the rear door glass sub-assembly into the rear door panel along the rear door glass run as indicated by the arrows in the order shown in the illustration.

(f) Install the rear door glass sub-assembly with the 2 bolts.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

HINT
Tighten the bolts in the order shown in the illustration.

20. INSTALL REAR DOOR REAR GUIDE SEAL

(a) Install the rear door rear guide seal with the 2 screws.

21. INSTALL REAR DOOR WINDOW REAR GUIDE SUB-ASSEMBLY

(a) Install the temporary screw to the rear door window division bar sub-assembly.

(b) Engage the claw, guide and temporarily install the rear door window rear guide sub-assembly.

Text in Illustration

(c) Install the bolt and screw.

(d) Tighten the temporary screw to install the rear door window rear guide sub-assembly.

22. INSTALL REAR DOOR VENT SEAL

(a) Install the rear door vent seal.

23. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.

24. INSTALL REAR DOOR WEATHERSTRIP

(a) Engage the 19 clips and install a new rear door weatherstrip.

Text in Illustration

25. INSTALL REAR DOOR CHECK ASSEMBLY

(a) Apply MP grease to the sliding areas of the rear door check assembly.

(b) Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the rear door check assembly with the bolt and 2 nuts.

Bolt - Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

Nut - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

26. INSTALL REAR DOOR CHECK COVER

(a) Install the rear door check cover.

27. INSTALL REAR DOOR SERVICE HOLE COVER

(a) Apply butyl tape to the rear door panel.

(b) 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.

(c) Attach the rear door service hole cover according to the reference points on the rear door panel.

Text in Illustration

NOTICE:
Securely install the rear door service hole cover preventing wrinkles and air bubbles.

(d) Connect the 2 connectors.

28. INSTALL REAR DOOR TRIM BRACKET

(a) Install the rear door trim bracket with the 2 screws.

29. INSTALL REAR DOOR FRAME GARNISH

(a) Engage the clip to install the rear door frame garnish.

(b) Install the 2 clips.

30. INSTALL REAR NO. 1 SPEAKER ASSEMBLY Installation

31. INSTALL REAR NO. 2 SPEAKER ASSEMBLY (for 12 or 15 Speakers) Installation

32. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 4 claws and install the rear door inner glass weatherstrip as shown in the illustration.

33. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) Install 2 new rear door trim board retainers (green).

(b) Connect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

(c) for 12 Speakers or 15 Speakers:

(1) Connect the connector.

(d) Engage the rear door trim board sub-assembly with the 4 claws of the rear door inner glass weatherstrip as shown in the illustration.

(e) Engage the 7 clips, 2 rear door trim board retainers and install the rear door trim board sub-assembly.

Text in Illustration

(f) Install the 3 screws.

(A) - Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)

34. INSTALL COURTESY LIGHT ASSEMBLY Installation

35. INSTALL REAR DOOR ARMREST COVER

(a) Install the rear door armrest cover.

36. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL

(a) Connect the connector.

(b) Engage the 2 clips and 3 claws, and install the rear power window regulator switch assembly with rear door armrest base panel.

37. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

(a) Engage the 3 claws and install the rear door inside handle bezel plug.

38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

39. INITIALIZE POWER WINDOW CONTROL SYSTEM

Initialization

40. INSTALL REAR DECK FLOOR BOX Installation

41. INSPECT SRS WARNING LIGHT

Diagnosis System