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Home >> Toyota >> 2016 >> Avalon XLE Plus >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (Except Hybrid) >> Rear Door >> Disassembly [10/2014 - ] >> Procedure

Disassembly [10/2014 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work (Refer to PRECAUTION [10/2014 - ] ).

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a moulding remover, disengage the 3 claws to remove the rear door inside handle bezel plug as shown in the illustration.
      GTY376956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL 
    1. Put protective tape around the rear door trim board sub-assembly.
    2. Using a moulding remover, disengage the clip, 7 claws and 2 guides.
      GTY383755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape
    3. Using a screwdriver, disengage the 2 clips and guide.
      GTY376953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

    4. w/ illumination:
      1. Disengage the 2 clamps.
        GTY582324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect each connector to remove the rear power window regulator switch assembly with rear door armrest base panel.
  5. REMOVE NO. 1 REAR DOOR STIFFENER CUSHION 
    1. Remove the screw and No. 1 rear door stiffener cushion.
      GTY469614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Put protective tape around the rear door panel.
      GTY376950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape
    2. Remove the 3 screws.
      GTY552485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a clip remover, disengage the 7 clips.
      GTY552484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Pull out the rear door trim board sub-assembly as shown in the illustration.
      GTY574135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Reference Boss
      *2 Rear Door Inner Glass Weatherstrip
      *3 Screwdriver
    5. Disengage the reference boss from the rear door panel.
    6. Using a screwdriver, disengage the claw as shown in the illustration.
    7. Raise the rear door trim board sub-assembly to disengage the 3 claws to remove the rear door trim board sub-assembly together with the rear door inner glass weatherstrip.
    8. Disconnect the rear door lock remote control cable assembly and rear door inside locking cable assembly.
      GTY360979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disconnect each connector and remove the rear door trim board sub-assembly.
    10. Remove the No. 1 door scuff plate clamp.
      GTY582649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the 2 claws and guide to remove the rear door inside handle sub-assembly.
      GTY582650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Using a screwdriver, disengage the 3 claws and remove the rear door inner glass weatherstrip from the rear door trim board sub-assembly as shown in the illustration.
      GTY539664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Screwdriver
  9. REMOVE REAR NO. 2 SPEAKER ASSEMBLY WITH BRACKET 

    Refer to PROCEDURE - Step 6

  10. REMOVE REAR REFLEX REFLECTOR ASSEMBLY 
    1. for LH Side:
      1. Disengage the 2 claws to remove the rear reflex reflector assembly.
        GTY582648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for RH Side:
      1. Disengage the 2 claws to remove the rear reflex reflector assembly.
        GTY582645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE REAR DOOR TRIM BRACKET 
    1. Remove the 2 screws and rear door trim bracket.
      GTY582646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE REAR DOOR SERVICE HOLE COVER 
    1. Disconnect the connector.
      GTY360975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear door service hole cover.

      HINT: 

      Remove any remaining butyl tape from the rear door panel.

  13. REMOVE REAR DOOR CHECK ASSEMBLY 
    1. Remove the bolt and 2 nuts, and rear door check assembly.
      GTY580507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Nut
  14. REMOVE REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 19 clips and remove the rear door weatherstrip.
      GTY582660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR DOOR GLASS RUN 
    1. Connect the cable to the negative (-) battery terminal.
    2. Connect the rear power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
    3. Disconnect the cable from the negative (-) battery terminal.
    4. Disconnect the rear power window regulator switch assembly.
    5. Remove the rear door glass run.
      GTY582655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts, 2 screws and rear door lower window frame sub-assembly.
      GTY544252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Screw
      NOTE:

      When the rear door lower window frame sub-assembly is removed, do not allow the rear door quarter window glass to fall.

  17. REMOVE REAR DOOR REAR GUIDE SEAL 
    1. Remove the 2 screws and rear door rear guide seal as shown in the illustration.
      GTY360949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      GTY582656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After the bolts are removed, do not allow the rear door glass sub-assembly to fall.

    2. Remove the rear door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.
      GTY370448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the rear door glass sub-assembly.

  19. REMOVE REAR DOOR FRAME GARNISH 
    1. Disengage the clip to remove the rear door frame garnish.
      GTY552488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      This garnish needs to be replaced with a new one because the clip will break when removing it.

  20. REMOVE REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY 
    1. Remove the 4 screws.
      GTY582692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide to remove the rear door inside panel reinforce sub-assembly.
  21. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. Disconnect the connector.
      GTY582830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Temporary Bolt
    2. Loosen the temporary bolt.
      NOTE:

      Do not remove the temporary bolt. If the temporary bolt is removed, the rear door window regulator assembly may fall and cause damage.

    3. Remove the 5 bolts.
    4. Remove the rear door window regulator assembly.
    5. Remove the temporary bolt from the rear door window regulator assembly.
  22. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    1. Using a T25 "TORX" socket wrench, remove the 3 screws and rear power window regulator motor assembly.
      GTY582690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the 3 screws.
      GTY574682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Release Plate
    2. Move the rear door lock with motor assembly downward and pull the release plate out of the rear door outside handle frame.
    3. When reusing the rear door lock with motor assembly:
      1. Remove the door lock wiring harness seal from the rear door lock with motor assembly.
        GTY582700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the claw.
      GTY360870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear door lock remote control cable assembly.
      GTY360831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 3 claws.
      GTY360853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear door inside locking cable assembly.
      GTY360829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE REAR DOOR OUTSIDE HANDLE COVER 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY582701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The screw cannot be removed because it is integrated into the rear door outside handle frame sub-assembly.

    2. Disengage the claw and remove the rear door outside handle cover.
  27. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Move the lever in the direction as shown in the illustration.
      GTY360840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull and hold the release plate of the rear door outside handle frame sub-assembly as shown in the illustration.
      GTY360842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The release plate may interfere with the rear door outside handle assembly and may be damaged when removing the rear door outside handle assembly, unless the release plate of the rear door outside handle frame sub-assembly is pulled and held.

    3. Remove the rear door outside handle assembly as shown in the illustration.
      GTY360826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws to remove the rear door front outside handle pad.
      GTY360897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws to remove the rear door rear outside handle pad.
      GTY360898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY598905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Outside
      *b Inside
    2. Slide the rear door outside handle frame sub-assembly to disengage the claw of the rear door outside handle frame sub-assembly, and then remove it.
  31. REMOVE REAR DOOR NO. 2 WEATHERSTRIP 
    1. Using a clip remover, disengage the 5 clips to remove the rear door No. 2 weatherstrip.
      GTY582694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REAR DOOR NO. 3 WEATHERSTRIP 
    1. Using a clip remover, disengage the clip and remove the rear door No. 3 weatherstrip.
      GTY564834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Double-sided Tape
  33. REMOVE REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 15

  34. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  35. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 4

  36. REMOVE REAR DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 5

  37. REMOVE NO. 1 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 2

  38. REMOVE NO. 3 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 3

  39. REMOVE NO. 2 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 4

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