Reassembly

DOOR / HATCH: REAR DOOR: REASSEMBLY

1. REPAIR INSTRUCTION

2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

3. INSTALL REAR DOOR OUTSIDE STRIPE

4. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY

5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

6. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY Installation

7. INSTALL NO. 3 REAR DOOR WEATHERSTRIP

HINT
When installing the No. 3 rear door weatherstrip, heat the vehicle body and No. 3 rear door weatherstrip using a heat light.

NOTICE:
Do not heat the vehicle body or No. 3 rear door weatherstrip excessively.

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

Heating Temperature

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

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

(d) Install a new No. 3 rear door weatherstrip.

Text in Illustration

8. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

9. INSTALL REAR DOOR PANEL CUSHION

(a) Engage the claw and install a new rear door panel cushion.

10. INSTALL NO. 2 REAR DOOR WEATHERSTRIP

(a) Engage the 4 clips to install the No. 2 rear door weatherstrip.

11. 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)

12. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

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

13. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

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

14. 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.

15. 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)

16. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

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

(b) Engage the 3 claws.

17. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

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

(b) Engage the claw.

18. 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)

(f) Engage the rear door lock remote control cable assembly and rear door inside locking cable assembly.

19. 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.

20. 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 3 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)

21. INSTALL NO. 2 REAR DOOR STIFFENER CUSHION

(a) When reusing the No. 2 rear door stiffener cushion:

(1) Clean the No. 2 rear door stiffener cushion.

(2) Remove the double-sided tape from the No. 2 rear door stiffener cushion.

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

(4) Apply new double-sided tape to the No. 2 rear door stiffener cushion as shown in the illustration.

(b) Clean the rear door panel sub-assembly.

(c) Engage the 2 guides.

Text in Illustration

(d) Insert the No. 2 rear door stiffener cushion with the 2 bolts.

22. INSTALL REAR DOOR GLASS CHANNEL FILLER

(a) Apply soapy water to a new rear door glass channel filler.

(b) Install the rear door glass channel filler to the position shown in the illustration.

Text in Illustration

23. INSTALL REAR DOOR GLASS CHANNEL SUB-ASSEMBLY

(a) Apply soapy water to the channel filler side of the rear door glass channel sub-assembly.

(b) Using a plastic hammer, install the rear door glass channel sub-assembly to the position shown in the illustration.

Text in Illustration

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

24. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

(a) Slide the rear door glass sub-assembly to install it as shown in the illustration.

25. INSTALL NO. 1 REAR DOOR VENT SEAL

(a) Install the No. 1 rear door vent seal.

26. INSTALL REAR DOOR QUARTER WINDOW GLASS

(a) Install the rear door quarter window glass to the rear door quarter window weatherstrip.

(b) 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.

27. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

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

(b) Temporarily install the rear door window division bar sub-assembly.

Text in Illustration

(c) Install the bolt and screw.

Bolt - Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(d) Tighten the temporary bolt to install the rear door window division bar sub-assembly.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

28. INSTALL NO. 2 REAR DOOR VENT SEAL

(a) Install the No. 2 rear door vent seal.

29. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.

30. INSTALL NO. 1 REAR DOOR WEATHERSTRIP

(a) Engage the 21 clips to install a new rear door weatherstrip.

Text in Illustration

31. INSTALL REAR DOOR CHECK ASSEMBLY

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the rear door check assembly with the 3 bolts.

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

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

32. INSTALL REAR DOOR CHECK COVER

(a) Install the rear door check cover.

33. 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 connector.

(e) Engage the clamp.

34. INSTALL REAR DOOR ARMREST SET BRACKET

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

35. INSTALL REAR DOOR FRAME GARNISH

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

36. INSTALL REAR SPEAKER ASSEMBLY Installation

37. INSTALL REAR NO. 2 SPEAKER ASSEMBLY Installation

38. INSTALL REAR DOOR TRIM SEAL

(a) Engage the 6 clips of the rear door trim seal.

39. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 3 claws and install the rear door inner glass weatherstrip as shown in the illustration.

40. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the claw and 2 guides, and install the rear door inside handle sub-assembly to the rear door trim board sub-assembly as shown in the illustration.

41. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

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

(b) Connect the connector.

(c) Engage the rear door trim board sub-assembly with the 3 claws to the rear door inner glass weatherstrip as shown in the illustration.

(d) Engage the 9 clips and install the rear door trim board sub-assembly.

(e) Install the 3 screws.

42. INSTALL NO. 1 REAR DOOR STIFFENER CUSHION

(a) Install the No. 1 rear door stiffener cushion with the screw.

43. INSTALL REAR DOOR ARMREST COVER

(a) Install the rear door armrest cover.

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

(a) Connect the connector.

(b) except Wood Panel:

(1) Engage the 2 clips, 6 claws and 2 guides, and install the rear power window regulator switch assembly with rear door armrest base panel.

(c) for Wood Panel:

(1) Engage the 4 clips, 4 claws and 2 guides, and install the rear power window regulator switch assembly with rear door armrest base panel.

45. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

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

46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

47. INITIALIZE POWER WINDOW CONTROL SYSTEM

Initialization

48. INSTALL LUGGAGE COMPARTMENT FLOOR MAT Installation