LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2021 >> UX 200 Base >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (1 Of 2) >> Rear Door >> Disassembly [10/2018 - 07/2022] >> Procedure

Disassembly [10/2018 - 07/2022]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to INITIALIZATION [10/2018 - 07/2022]

  2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [10/2018 - 07/2022]

  3. REMOVE REAR DOOR ARMREST COVER 
    GTY831035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using moulding remover A, remove the rear door armrest cover.
  4. REMOVE REAR DOOR TRIM COVER 
    GTY822297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Protective Tape
    Remove in this Direction
    1. Using a screwdriver with its tip wrapped in protective tape, disengage the claws to remove the rear door trim cover as shown in the illustration.
  5. REMOVE REAR ARMREST ASSEMBLY 
    1. Disengage the clips and claws as shown in the illustration.
      GTY828954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Disengage the retainer to remove the rear armrest assembly.
      GTY793492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE UPPER PANEL 
    GTY802575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Remove in this Direction
    1. Disengage the clips and claws to remove the power window regulator switch assembly with rear door armrest base upper panel as shown in the illustration.
    2. Disconnect the connector.
      GTY793619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 3 screws.
      GTY834190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clips to remove the rear door trim board sub-assembly as shown in the illustration.
      GTY786886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
    3. Disengage the guide to disconnect the rear door lock remote control cable assembly from the rear door trim board sub-assembly.
      GTY799274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Door Lock Remote Control Cable Assembly
    4. Disengage the claws as shown in the illustration.
      GTY788164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  8. REMOVE REAR DOOR INSIDE HANDLE BEZEL 
    1. Remove the screws.
      GTY819978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Disengage the claws to remove the rear door inside handle bezel as shown in the illustration.
  9. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Remove the 3 screws.
      GTY806806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw and guide to remove the door inside handle sub-assembly.
  10. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Disengage the claws to remove the rear door inner glass weatherstrip as shown in the illustration.
      GTY800520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  11. REMOVE REAR DOOR LOCK CONTROL KNOB BEZEL 
    1. Disengage the claws to remove the rear door lock control knob bezel as shown in the illustration.
      GTY796068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  12. REMOVE REAR DOOR TRIM BRACKET 
    1. Remove the 2 screws and rear door trim bracket.
      GTY806889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  14. REMOVE NO. 3 REAR DOOR SERVICE HOLE COVER 
    1. Remove the 4 screws and No. 3 rear door service hole cover.
      GTY806885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR DOOR SERVICE HOLE COVER 
    1. Disconnect the 2 connectors.
      GTY807619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Move the wire harness out of the way and remove the rear door service hole cover.

      HINT: 

      Remove any remaining butyl tape from the rear door panel.

  16. REMOVE REAR DOOR FRAME GARNISH 
    1. Disengage the clips and guides to remove the rear door frame garnish as shown in the illustration.
      GTY792201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  17. REMOVE NO. 2 REAR DOOR SERVICE HOLE COVER 
    1. Remove the No. 2 rear door panel service hole cover as shown in the illustration.
      GTY837992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  18. REMOVE NO. 2 REAR DOOR VENT SEAL 
    1. Remove the No. 2 rear door vent seal as shown in the illustration.
      GTY818780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  19. REMOVE REAR DOOR GLASS RUN 
    1. Remove the hole plug.
      GTY807621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the power window regulator switch assembly with rear door armrest upper base panel.
    3. Connect the cable to the auxiliary battery negative (-) terminal.
    4. Move the rear door window regulator so that the rear door glass bolts can be seen.
    5. Disconnect the cable from the auxiliary battery negative (-) terminal.
    6. Disconnect the power window regulator switch assembly with rear door armrest upper base panel.
    7. Remove the rear door glass run.
      GTY807624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Raise up the No. 2 rear door weatherstrip.
    2. Insert a 4.0 mm (0.157 in.) drill bit into a drill.
    3. Tape the 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.
      GTY572016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tape

      Standard Measurement

      Area Measurement
      A 5.0 mm (0.197 in.)
      NOTE:

      Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

    4. Lightly press the drill bit against the rivets to drill off the rivet flanges, and remove the rivet.
      WARNING:

      Be careful of the drilled rivets, as they may be hot.

      NOTE:
      • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.
      • Prying the rivets with the drill may damage the rivet installation holes or drill bit.
      GTY835793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tape
    5. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas.
    6. Remove the 2 bolts and rear door window division bar sub-assembly.
  21. REMOVE REAR DOOR QUARTER WINDOW GLASS 
    1. Remove the rear door quarter window glass with rear door quarter window weatherstrip as shown in the illustration.
      GTY781528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  22. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP 
    1. Remove the rear door quarter window weatherstrip.
      GTY807561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      GTY834376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear door glass sub-assembly as shown in the illustration.
      NOTE:

      Do not damage the rear door glass.

      GTY809656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  24. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Remove the 6 nuts and rear door window regulator sub-assembly.
      GTY807555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 15

  26. REMOVE REAR DOOR LOCK CHILD PROTECTION COVER 
    1. Remove the rear door lock child protection cover.
      GTY807564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE REAR DOOR LOCK COVER SUB-ASSEMBLY 
    1. Remove the rear door lock cover sub-assembly.
      GTY834383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Disengage the claws to remove the holder as shown in the illustration.
      GTY832263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Holder
      Remove in this Direction
    2. Remove the rear door outside handle assembly as shown in the illustration.
      GTY835437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  29. REMOVE REAR DOOR OUTSIDE HANDLE COVER 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY837409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Remove the rear door outside handle cover as shown in the illustration.
  30. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the claws to remove the rear door front outside handle pad as shown in the illustration.
      GTY782715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  31. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the claws to remove the rear door rear outside handle pad as shown in the illustration.
      GTY831907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  32. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the screw and front door outside handle frame sub-assembly.
      GTY807553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE REAR DOOR HANDLE NUT 
    1. Remove the rear door handle nut as shown in the illustration.
      GTY818830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  34. REMOVE REAR DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts and rear door check assembly.
      GTY807590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the clips.
      GTY799077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Double-sided Tape
    2. Peel off the double-sided tape to remove the rear door weatherstrip.
      NOTE:

      Remove any remaining double-sided tape from the rear door panel.

  36. REMOVE NO. 2 REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the clips.
      GTY815983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Double-sided Tape
    2. Peel off the double-sided tape to remove the No. 2 rear door weatherstrip.
      NOTE:

      Remove any remaining double-sided tape from the rear door panel.

  37. REMOVE REAR DOOR PANEL CUSHION 
    1. Remove the rear door panel cushion.
      GTY807588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  39. REMOVE REAR DOOR DUST PROOF SEAL 
    1. Remove the 3 rear door dust proof seals.
      GTY807587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 5 REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the clip.
      GTY789538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Double-sided Tape
    2. Peel off the double-sided tape to remove the No. 5 rear door weatherstrip.
      NOTE:

      Remove any remaining double-sided tape from the rear door panel.

  41. REMOVE REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 16

  42. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  43. REMOVE REAR DOOR FRONT OUTSIDE SEAL 
    1. Remove the rear door front outside seal.
      GTY835824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 3 REAR DOOR WEATHERSTRIP 
    1. Peel off the double-sided tape to remove the No. 3 rear door weatherstrip.
      NOTE:

      Remove any remaining double-sided tape from the rear door panel.

      GTY807034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Double-sided Tape
  45. REMOVE REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  46. REMOVE HOLE PLUG 
    1. Remove the 3 hole plugs.
      GTY807586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE REAR DOOR OUTSIDE PANEL REINFORCEMENT LINING 
    1. Remove the rear door outside panel reinforcement lining.
      GTY807603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Remove any remaining butyl tape from the rear door panel.

scientia non olet · About LEMON Manuals