REAR DOOR (for Hatchback without Power Window): Disassembly

HINT:

• Use the same procedure for both the RH and LH side.
• The procedure described below is for the LH side.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
2. REMOVE DOOR WINDOW REGULATOR HANDLE ASSEMBLY 
   1. Insert a clip remover between the plate and door trim.
   2. Turn the handle with the clip remover inserted.
   3. Remove the rear door window regulator handle assembly and clip.
   4. Remove the window regulator handle plate.
      Fig 1: Turning Handle With Clip

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY 
   1. Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws and remove the rear door armrest plug.
      Fig 2: Identifying Claws Location

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the 2 screws.
      Fig 3: Locating Screws

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   3. Disengage the 7 clips.
   4. Disconnect the connector.
      Fig 4: Identifying Clips Location

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Disconnect the rear door lock remote control cable and rear door inside locking cable and remove the rear door trim board.
      Fig 5: Identifying Rear Door Lock Remote Control Cable & Rear Door Inside Locking Cable

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
   1. Disengage the 6 claws and remove the rear door inside handle.
5. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER 
   1. Remove the rear door glass weatherstrip inner from the rear door trim board.
6. REMOVE REAR SPEAKER ASSEMBLY (w/ Rear Speaker) (See  REMOVAL  ) 
   Fig 6: Identifying Claws Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE REAR DOOR SERVICE HOLE COVER 
   1. w/ Rear speaker:

      Disconnect the connectors and clamps, then remove the rear door service hole cover.

      NOTE: Remove any tape remaining on the door side.
      Fig 7: Identifying Rear Door Service Hole Cover (With Rear Speaker)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. w/o Rear speaker:

      Disconnect the connectors and clamps, then remove the rear door service hole cover.

      NOTE: Remove any tape remaining on the door side.
      Fig 8: Identifying Rear Door Service Hole Cover (Without Rear Speaker)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE REAR DOOR CHECK ASSEMBLY 
   1. Remove the 3 bolts, then remove the rear door check.
      NOTE: Do not drop or damage the door check when removing the bolts.

      HINT:

      Remove the door check through the service hole.

      Fig 9: Identifying Rear Door Check Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE REAR DOOR WEATHERSTRIP 
   1. Disengage the 32 clips and remove the rear door weatherstrip.
      NOTE: Remove any tape remaining on the door side.
10. REMOVE REAR DOOR BELT MOLDING (See  REMOVAL  ) 
    Fig 10: Identifying Clips Location

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE REAR DOOR GLASS RUN 
    1. Remove the rear door glass run.
       Fig 11: Identifying Rear Door Glass Run

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Remove the 2 bolts and screw and rear door window division bar.
       NOTE: Do not drop or damage the rear door window division bar when removing the bolts and screw.
       Fig 12: Locating Bolts & Rear Door Window Division Bar

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP 
    1. Slide the rear door quarter window weatherstrip, in the direction indicated by the arrow, to remove it.
    2. Remove the rear door quarter window glass from the rear door quarter window weatherstrip.
       Fig 13: Sliding Rear Door Quarter Window Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. Remove the rear door glass from the rear door window regulator.
       Fig 14: Identifying Rear Door Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Loosen bolt A.
    2. Remove the 2 bolts, then remove the rear door window regulator.
       NOTE: Do not drop or damage the window regulator when removing the bolts.

       HINT:

       Remove the window regulator through the service hole.

       Fig 15: Identifying Bolts & Rear Door Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE REAR DOOR OUTSIDE HANDLE COVER 
    1. Using "Torx" socket wrench T30, remove the screw and rear door outside handle cover.
       Fig 16: Locating Screw & Rear Door Outside Handle Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE REAR DOOR LOCK ASSEMBLY 
    1. Using "Torx" socket wrench T30, remove the 3 screws.
    2. Move the rear door lock downward, remove the outside handle frame release plate and remove the rear door lock.
       NOTE: Do not drop or damage the door lock when removing the bolts.

       HINT:

       Remove the rear door lock through the service hole.

       Fig 17: Locating "Torx" Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 7 claws and open the 2 covers.
       Fig 18: Locating Covers

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    4. Disconnect the rear door lock remote control cable and rear door inside locking cable.
    5. Remove the door lock wire harness seal.
       Fig 19: Locating Rear Door Lock Remote Control Cable & Rear Door Inside Locking Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark.
       Fig 20: Pulling Rear Door Outside Handle Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE REAR DOOR OUTSIDE HANDLE PAD REAR 
    1. Disengage the 2 claws and remove the rear door outside handle pad rear.
       Fig 21: Identifying Claws Location

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE REAR DOOR OUTSIDE HANDLE PAD FRONT 
    1. Using "Torx" socket wrench T30, loosen the screw.
       Fig 22: Identifying "Torx" Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws and remove the rear door outside handle pad front.
       Fig 23: Identifying Claws Location

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Slide the outside handle frame to remove it.
       Fig 24: Sliding Outside Handle Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002