Reassembly

DOOR / HATCH: REAR DOOR: REASSEMBLY

1. INSTALL CUSHION

(a) Install the cushions onto the door panel.





2. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Slide the rear door outside handle frame subassembly and engage the claw and install it.





(b) Using a T30 "TORX" wrench, tighten the screw

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

3. INSTALL REAR DOOR OUTSIDE HANDLE FRONT PAD

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





4. INSTALL REAR DOOR OUTSIDE HANDLE REAR PAD

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





5. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

(a) Install the rear door outside handle assembly by pushing it in the direction indicated by the arrow mark shown in the illustration.





6. INSTALL REAR DOOR OUTSIDE HANDLE COVER

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





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

7. INSTALL REAR DOOR LOCK Installation

8. INSTALL REAR DOOR NO. 2 WEATHERSTRIP





(a) Engage the 17 clips and install the rear door No. 2 weatherstrip.

9. INSTALL REAR DOOR WEATHERSTRIP





(a) Engage the 42 clips and install the rear door weatherstrip.

10. INSTALL REAR DOOR CHECK ASSEMBLY





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

(b) Install the rear door check assembly onto the door panel with the 2 nuts.

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent

(d) Install the rear door check assembly onto the body panel with the bolt.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

11. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY

(a) Apply MP grease to the sliding and rotating areas of the rear door window regulator sub-assembly.





NOTICE:
Do not apply grease to the front door window regulator spring.

(b) Loosely screw bolt A onto the rear door window regulator sub-assembly.

(c) Insert the rear door window regulator sub-assembly into the door panel. Provisionally tighten bolt A to hang the rear door window regulator sub-assembly on the door panel.

NOTICE:
Do not drop the front door window regulator sub-assembly as it may be damaged.

(d) Install the front door window regulator sub-assembly with the 5 bolts, and tighten bolt A.

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

(e) Connect the connector.

12. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

(a) Install the rear door glass sub-assembly onto the rear door window regulator with the 2 bolts.





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

13. INSTALL REAR DOOR WINDOW GUIDE FRONT SUB-ASSEMBLY

(a) Install the rear door window guide front sub-assembly with the 2 bolts





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

14. INSTALL REAR DOOR WINDOW FRAME REAR LOWER SUB-ASSEMBLY





(a) Install the rear door window frame rear lower sub-assembly with the nut and 3 bolts.

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

15. INSTALL REAR DOOR FRAME BRACKET

(a) Engage the claw and install the sunshade hook.





16. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.





17. INSTALL REAR DOOR GLASS OUTER WEATHERSTRIP

18. INSTALL REAR DOOR WINDOW FRAME REAR MOULDING

19. INSTALL REAR DOOR SERVICE HOLE COVER

(a) Apply butyl tape to the door panel, then install a new rear door service hole cover as shown in the illustration.

HINT
* When installing the service hole cover, pull the links and connectors out through the service hole.
* There should be no wrinkles or folds after attaching the service hole cover.
* After attaching the service hole cover, check the quality of the seal.





(b) Engage the clamps and connect the connectors.





20. INSTALL REAR DOOR TRIM NO. 2 BRACKET

(a) Install the rear door trim No. 2 bracket with the 2 screws.





21. INSTALL REAR NO. 1 SPEAKER ASSEMBLY Installation

22. INSTALL REAR DOOR GLASS INNER WEATHERSTRIP

(a) Install the rear door glass inner weatherstrip on the rear door trim board sub-assembly and fold down the 8 claws, as shown in the illustration.





23. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Install the rear door inside handle sub-assembly with the 3 screws.





24. INSTALL REAR DOOR INSIDE HANDLE BEZEL

(a) Install the rear door inside handle bezel with the 4 screws.





25. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

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





(b) Connect the connector.

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





(d) Tighten the 2 screws.





(e) Install the rear door armrest cover.

26. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG





(a) Engage the 4 claws and install the rear door inside handle bezel plug.

27. INSTALL REAR DOOR ARMREST BASE UPPER PANEL

(a) Connect the connector.

(b) Engage the 2 clips and 5 claws and install the rear door armrest base upper panel.





28. INSTALL REAR DOOR FRAME GARNISH

(a) Engage the 6 clips and install the rear door frame garnish.





29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

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

30. INSPECT SRS WARNING LIGHT

(a) Inspect the SRS warning light Diagnosis System.