Rear Door: Reassembly

INSTALL REAR DOOR WEATHERSTRIP
INSTALL WINDOW FRAME FRONT MOLDING
Install the window frame front molding with the 3 screws.

Fig 1: Installing Window Frame Front Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WINDOW FRAME UPPER MOLDING
Using an air riveter with nose piece No. 1, install 6 new rivets and molding.

Fig 2: Installing Window Frame Upper Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
- Prizing a riveter leads to damage to the riveter, loose tightening and bending the mandrel.
  
  Fig 3: Tightening And Bending Mandrel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the material.
  
  Fig 4: Identifying Wrong Methods Of Riveting
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Loose tightening also occurs when a rivet is applied between materials without touching.
INSTALL NO. 2 REAR DOOR WEATHERSTRIP
Install the No. 2 rear door weatherstrip with the clip.
INSTALL OUTSIDE HANDLE PLUG, OUTSIDE HANDLE AND OUTSIDE HANDLE FRAME
1. Install the outside handle frame with the nut.
  
  Fig 6: Installing Outside Handle Frame With Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
2. Install the outside handle front pad.
3. Hold the outside handle frame with your hand, and slide the outside handle forward to install it.
  
  Fig 7: Installing Outside Handle Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  CAUTION: Do not damage the body surface.
4. Install the outside handle rear pad.
5. Install the outside handle plug with the bolt.
  
  Fig 8: Installing Outside Handle Plug With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
W/O Door Closer: INSTALL DOOR LOCK
NOTE: Apply MP grease to the sliding and rotating parts of the door lock.
1. Install the door lock remote control cable and door inside locking cable.
  
  Fig 9: Installing Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a torx wrench, install the 3 screws and door lock.
  
  Fig 10: Installing Screws And Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  NOTE: Apply adhesive to the 3 torx screws.
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
3. Connect the connector.
W/ Door Closer: INSTALL DOOR CLOSER
NOTE: Apply MP grease to the sliding and rotating parts of the door closer.
1. Install the door lock remote control cable and door inside locking cable.
  
  Fig 11: Installing Door Lock Remote Control Cable And Door Inside Locking Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a torx wrench, install the 4 screws and door closer.
  
  Fig 12: Installing Screws And Door Closer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  NOTE: Apply adhesive to the 4 torx screws.
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
3. Connect the connector and wire harness clamps.
INSTALL REAR DOOR QUARTER WINDOW GLASS
1. Install the quarter window weatherstrip to the glass.
2. Install the rear door quarter window glass as shown in Fig 13.
CAUTION: Do not damage the glass.
INSTALL DOOR WINDOW FRONT GUIDE SUB-ASSEMBLY
Install the door window front guide sub-assembly with the 2 bolts.

Fig 14: Installing Door Window Front Guide Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL WINDOW REGULATOR MOTOR
NOTE: If having rotated the motor only, reset the motor. See HOW TO RESET POWER WINDOW MOTOR (RESET SWITCH AND PULSE SWITCH) .

NOTE: Never rotate the motor to the down direction until the complete of the window glass installation.
1. Align the matchmarks on the window regulator motor bracket and regulator gear.
2. Using a torx wrench, install the 3 screws and motor.
INSTALL WINDOW REGULATOR
NOTE: Apply MP grease to the sliding and rotating parts of the window regulator.

Fig 16: Locating Areas For MP Grease
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the regulator through the service hole with the 4 bolts.
  
  Fig 17: Installing Regulator With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
2. Connect the connector.
INSTALL DOOR GLASS
NOTE: Insert a shop rag inside the door panel to prevent scratching the glass.
1. Install the glass channel filler and glass channel sub-assembly.
2. Put the door glass in the door panel carefully.
  CAUTION: Do not damage the door glass.
  
  Fig 18: Installing Glass Channel Filler And Glass Channel Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the door glass to the window regulator with the 2 nuts.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
INSTALL DOOR WINDOW REAR GUIDE SUB-ASSEMBLY AND DOOR GLASS RUN
1. Install the door window rear guide sub-assembly to the door glass run.
2. Install the door glass run together with door window rear guide sub-assembly.
3. Install the 2 nuts and bolt.
  
  Fig 20: Installing Nuts And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
4. Using an air riveter with nose piece No. 1, install 3 new rivets and glass run.
  
  Fig 21: Installing Rivets And Glass Run
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CAUTION:
- Prizing a riveter leads to damage to the riveter, loose tightening and bending the mandrel.
  
  Fig 22: Tightening And Bending The Mandrel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the material.
  
  Fig 23: Identifying Wrong Installation Methods For Rivets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Loose tightening also occurs when a rivet is applied between materials without touching.
  
  Fig 24: Identifying Wrong Installation Method For Rivets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DOOR BELT MOLDING
Install the door belt molding as shown in Fig 25.

Fig 25: Installing Door Belt Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SERVICE HOLE COVER

Fig 26: Installing Hole Cover

INSTALL DOOR ECU
1. Install the door ECU with the 2 screws.
2. Connect the connectors.
INSTALL DOOR SPEAKER
1. Install the door speaker with the 3 screws.
2. Connect the connector.
INSTALL DOOR FRAME GARNISH
Install the door frame garnish with the 2 clips.
W/Rear Curtain: INSTALL REAR CURTAIN SUB-ASSEMBLY
Install the rear curtain sub-assembly with the 4 screws.

Fig 27: Installing Rear Curtain Sub-Assembly With Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
W/ Tweeter: INSTALL TWEETER SPEAKER
Install the tweeter speaker to the door trim with the 3 screws.
INSTALL INSIDE DOOR HANDLE
1. w/ Seat memory:
  Install the seat memory switch to the inside handle bezel.
2. Install the No. 1 illumination light assembly to the inside handle bezel.
3. Engage the 2 claws and install the inside door handle.
4. Install the screw.
INSTALL DOOR TRIM
1. Connect the 2 cables to the inside handle of the door trim.
2. Connect the connectors.
3. Install the door trim with the 6 screws.
W/O Rear Side Curtain: INSTALL NO. 2 DOOR FRAME GARNISH
W/ Rear Side Curtain: INSTALL REAR SIDE CURTAIN ASSEMBLY
INSTALL COURTESY LIGHT ASSEMBLY
INSTALL ARMREST BASE PANEL ASSEMBLY
1. Install the upper armrest base panel with the screw.
2. Connect the connector and ash receptacle light, and install the armrest base panel assembly.
INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL

Fig 30: Installing No. 2 Door Inside Handle Bezel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002