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Section 1024 (Rear Door): Reassembly

WARNING: This page is about a different car, the 2004 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL CUSHIONS 
  2. INSTALL OUTSIDE HANDLE 

    Install the outside handle and rear door outside reinforcement extension with the 2 bolts.

    1. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 
    Fig 1: Installing Outside Handle & Rear Door Outside Reinforcement Extension With Bolts
    G03494602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL DOOR LOCK 
    1. Connect the connector.
    2. Using a torx socket wrench, install the door lock with the 3 torx screws.
      • Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 
      • Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool) 
      Fig 2: Installing Door Lock With Torx Screws
      G03494603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Apply adhesive to the 3 torx screws.

      Part No. 08833-00070, THREE BOND 1324 or equivalent 

    3. Install the bolt and screw.
    4. Connect the 2 links to the outside handle and key cylinder.
    5. Install the child protection cover.
  4. INSTALL WINDOW REGULATOR 

    HINT:

    Apply MP grease to the sliding and rotating parts of the window regulator.

    Fig 3: Applying MP Grease To Sliding & Rotating Parts
    G03494604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the window regulator with the 4 bolts.

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

      Fig 4: Installing Window Regulator Bolts
      G03494605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector.
  5. INSTALL DOOR GLASS 

    HINT:

    Insert a shop rag inside the door panel to prevent scratching the glass.

    Tilt the door glass and connect the roller of the regulator to the glass channel to install the door glass.

    Fig 5: Installing Door Glass
    G03494606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL QUARTER WINDOW GLASS 
    1. Install the quarter window weatherstrip to the glass.
      NOTE: Do not damage the glass. 
    2. Install the rear door quarter window glass as shown in Fig 6 .
    Fig 6: Installing Quarter Window Glass
    G03494607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL DIVISION BAR 
    1. Insert the division bar to the door panel, then rotate it 90°.
      Fig 7: Inserting Division Bar To Door Panel
      G03494608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 bolts and screw.
    Fig 8: Installing Division Bar Bolts & Screw
    G03494609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL DOOR GLASS RUN 
  9. INSTALL REAR DOOR BELT MOLDING 

    Install the rear door belt molding with the screw.

    Fig 9: Installing Rear Door Belt Molding
    G03494610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL SERVICE HOLE PLATE 

    Install the service hole plate with the 2 screws.

  11. INSTALL SERVICE HOLE COVER 
    1. Install the service hole cover to the door panel.

      HINT:

      • When installing the service hole cover, pull out the links and connectors through the service hole cover.
      • There should be no wrinkles or folds after attaching the service hole cover.
      • After attaching the service hole cover, sealing condition should be confirmed.
    2. Install the door trim bracket with the 2 screws.
      Fig 10: Installing Door Trim Bracket With Screws
      G03494611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
  12. INSTALL INSIDE HANDLE 

    Connect the 2 cables to the inside handle, then install the inside handle with the screw.

    Fig 11: Connecting Cables To Inside Handle
    G03494612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: At the time of locking cable reassembly, please refer to the following items. 
    • Set the door lock assembly to the LOCK position.
    • Hold the lock knob to the LOCK position by hand, and do not pull the cable while connecting the locking cable.
  13. INSTALL DOOR TRIM 

    Install the door trim to the door panel.

    Fig 12: Installing Door Trim To Door Panel
    G03494613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL REAR ARMREST 

    Install the rear armrest with the screw.

    Fig 13: Installing Rear Armrest
    G03494614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL POWER WINDOW SWITCH 
    1. Connect the connector.
    2. Install the power window switch to the door trim.
  16. INSTALL DOOR INSIDE HANDLE BEZEL 
    1. Install the door inside handle bezel with the screw.
      Fig 14: Installing Door Inside Handle Bezel
      G03494615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Close the cap.
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