Rear Door: Disassembly

HINT:

• Use the same procedures for the LH side and RH side.
• The procedures listed below are for the RH side.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
   CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
2. REMOVE NO. 2 DOOR INSIDE HANDLE BEZEL 
   1. Using a screwdriver, remove the No. 2 door inside handle bezel as shown in Fig 1.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Removing No. 2 Door Inside Handle Bezel Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE NO. 1 DOOR INSIDE HANDLE BEZEL 
   1. Remove the screw.
   2. Using a screwdriver, remove the No. 1 door inside handle bezel as shown in Fig 2.

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Removing No. 1 Door Inside Handle Bezel Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY 
   1. Using a screwdriver, remove the power window switch as shown in Fig 3.

      HINT:

      Tape the screwdriver tip before use.

   2. Disconnect the connector.
      Fig 3: Removing Power Window Switch Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE REAR DOOR COURTESY LIGHT ASSEMBLY 
   1. Using a screwdriver, remove the door courtesy light, and then disconnect the connector.

      HINT:

      Tape the screwdriver tip before use.

      Fig 4: Removing Door Courtesy Light Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY 
   1. Remove the 3 screws and 4 clips.
   2. Insert a screwdriver between the door and door trim to pry the trim.
      NOTE: Be careful not to damage the door and door trim.

      HINT:

      Tape the screwdriver tip before use.

   3. Pull the trim upward to remove it.
      Fig 5: Removing Rear Door Trim Board Sub-Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE REAR DOOR INSIDE HANDLE SUBASSEMBLY 
   1. Remove the screw and the inside handle.
   2. Disconnect the 2 control cables from the inside handle as shown in Fig 6.
   Fig 6: Disconnecting Control Cables From Inside Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE REAR SPEAKER ASSEMBLY 
   1. Remove the 3 screws and speaker, and then disconnect the connector.
9. REMOVE REAR DOOR SERVICE HOLE COVER 
   1. Remove the clamps and wire harness.
   2. Remove the service hole cover.
      NOTE: Do not tear the cover.

      HINT:

      At the time of reassembly, bring out the 2 control cables and wire harness through the service hole cover.

      Fig 7: Removing Service Hole Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE REAR DOOR BELT MOLDING ASSEMBLY 
    1. Using a scraper, remove the door belt molding.

       HINT:

       Tape screwdriver tip before use.

    Fig 8: Removing Door Belt Molding

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE REAR DOOR GLASS RUN 
12. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Remove the 2 bolts, screw and division bar.
    Fig 9: Removing Division Bar

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. Disconnect the glass from the regulator arm and remove the door glass by pulling it upward.
14. REMOVE QUARTER WINDOW GLASS WITH WEATHERSTRIP 
15. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY 
    1. Disconnect the connector, and then remove the 3 bolts for bolt B.

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

    2. Loosen the bolt and window regulator for bolt A.

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

       HINT:

       • Remove the regulator through the service hole.
         Fig 10: Removing Regulator Through Service Hole

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • At the time of reassembly, apply MP grease to the window regulator.
         Fig 11: Applying MP Grease To Window Regulator

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
         NOTE: At the time of reassembly, please refer to the following item.
         Do not apply grease to the spring of the window regulator.
16. REMOVE REAR DOOR LOCK ASSEMBLY 
    1. Remove the screw.
    2. Disconnect the connector.
    3. Disconnect the link from outside handle.
    4. Using a "torx" wrench, remove the 3 screws and door lock through the service hole.
       • "Torx" wrench: T30 (Part No. 09042-00010 or locally manufactured tool) 
       • Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 
       Fig 12: Removing Door Lock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       At the time of reassembly:

       • Apply adhesive to the 3 screws.

         Adhesive: 

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

       • Remove the protector, and apply MP grease to the sliding and rotating parts of the door lock.
17. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Remove the 2 bolts and outside handle.

       Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

       Fig 13: Removing Outside Handle

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002