Rear Door: Disassembly

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (See STANDARD BOLT ).

1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH 
   1. Using a screwdriver, disengage the 3 claws and remove the rear door inside handle bezel plug LH.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Disengaging Claws And Removing Rear Door Inside Handle Bezel Plug LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE REAR DOOR ARMREST BASE PANEL UPPER LH 
   1. Using a screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel upper LH with the power window regulator master switch.
      Fig 2: Disengaging Clips, Claws And Removing Armrest Base Panel Upper LH With Power Window Regulator Master Switch

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Disconnect the switch connector.
3. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH 
   1. Remove the 3 screws.
      Fig 3: Removing Rear Door Trim Board Subassembly Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a clip remover, disengage the 7 clips (A) and 4 clips (B) on top.
      Fig 4: Disengaging Rear Door Trim Board Subassembly Clips

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Remove the trim inboard.

      HINT:

      If a clip cannot be reached with the clip remover, pull on the lower trim to remove it.

   4. Disconnect the 2 cables.
      Fig 5: Disconnecting Cables

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   5. Disconnect the wire harness connector from the courtesy lamp.
   6. Remove the 4 screws and the rear door inside panel bracket No. 1 LH.
4. REMOVE REAR SPEAKER ASSEMBLY NO.2 
   1. Remove the rear speaker assembly No. 2 (See step 12 under REMOVAL ).
      Fig 6: Removing Rear Speaker Assembly No. 2

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5. REMOVE REAR SPEAKER ASSEMBLY 
   1. Remove the rear speaker assembly (See step 4 under REMOVAL ).
6. REMOVE REAR DOOR SERVICE HOLE COVER LH 
   1. Remove the rear door service hole cover LH.
      NOTE: Remove the remaining tape on the door side.
      Fig 7: Removing Remaining Tape On Door Side

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE REAR DOOR BELT MOULDING ASSEMBLY LH 
8. REMOVE REAR DOOR WINDOW FRAME MOULDING FRONT LH 
9. REMOVE REAR DOOR MOULDING SUB-ASSEMBLY OUTSIDE LH 
10. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER LH 
11. REMOVE POWER DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH 
    1. Remove the screw, 2 bolts and the rear door window division bar sub-assembly LH.
12. REMOVE REAR DOOR WINDOW GLASS LH 
    1. Remove the rear door window glass LH as shown in Fig 8.
       Fig 8: Removing Rear Door Window Glass LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH 
    1. Separate the arm of the rear door window regulator from the rail of the rear door glass.
    2. Remove the rear door glass sub-assembly LH
       NOTE: Be careful not to damage the glass.
       Fig 9: Removing Rear Door Glass Sub-Assembly LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH 
    1. Remove the 4 bolts and the rear door window regulator sub-assembly LH.
       Fig 10: Removing Bolts And Rear Door Window Regulator Sub-Assembly LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY RH REAR 
    1. Using a torx wrench (T25), remove the 3 torx screws and the power window regulator motor assembly RH rear.
       Fig 11: Removing Torx Screws And Power Window Regulator Motor Assembly RH Rear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE REAR DOOR WINDOW RUN LH 
17. REMOVE REAR DOOR WITH MOTOR ASSEMBLY LH 
    1. Disconnect the door lock connector.
    2. Using a torx socket wrench (T30), remove the 3 torx screws and rear door w/motor lock assembly LH.
       Fig 12: Removing Torx Screws And Rear Door W/Motor Lock Assembly LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       Remove the door lock through the service hole.

       NOTE: Be careful when removing the bolts as the door lock may fall and be damaged.
18. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH 
    1. Using a torx socket wrench (T30), loosen the torx screw and remove the cover with the door lock key cylinder installed.
       Fig 13: Removing Cover With Door Lock Key Cylinder Installed

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH 
    1. Remove the handle by sliding and pulling it in the direction indicated by the arrow in Fig 14.
       Fig 14: Removing Handle By Sliding And Pulling In Direction Indicated

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the outside handle pad front and rear.
       NOTE: If the bellcrank lever is not pulled and held when removing the handle, the release plate will interfere with the handle and be damaged.
20. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Using a torx socket wrench (T30), loosen the torx screw and remove the rear door outside handle frame sub-assembly LH.
       Fig 15: Loosening Torx Screw And Removing Rear Door Outside Handle Frame Sub-Assembly LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Disconnect the connectors.
    2. Disconnect the clamp.
       Fig 16: Disconnecting Connectors And Clamp

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a torx socket wrench, loosen the torx screw and remove the rear door outside handle frame subassembly LH.
       Fig 17: Loosening Torx Screw And Removing Rear Door Outside Handle Frame Subassembly LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE REAR DOOR OUTSIDE HANDLE PAD FRONT 
23. REMOVE REAR DOOR OUTSIDE HANDLE PAD REAR 
24. REMOVE REAR DOOR CHECK ASSEMBLY LH 
    1. Remove the bolt, 2 nuts and the rear door check assembly LH.

       HINT:

       Remove the door check through the service hole.

       NOTE: Be careful when removing the bolts as door check may fall and be damaged.
       Fig 18: Removing Bolt, Nuts And Rear Door Check Assembly LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE REAR DOOR WEATHERSTRIP LH