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Home >> Toyota >> 2016 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 122 ((Door / Hatch) (Service Information) (Hybrid) (2 Of 2)) >> Rear Door >> Disassembly [02/2014 - 11/2015] >> Procedure

Disassembly [02/2014 - 11/2015]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    NOTE:

    After turning the power 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 PRECAUTION [02/2014 - 11/2016]

  2. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 1

  3. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. 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 [02/2014 - 11/2016]

  5. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a moulding remover, disengage the 3 claws and remove the rear door inside handle bezel plug.
      GTY424400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR UPPER ARMREST BASE PANEL 
    1. Using a moulding remover, disengage the 2 clips, 2 claws and 2 guides.
      GTY450533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector and remove the rear power window regulator switch assembly with rear door upper armrest base panel.
  7. REMOVE REAR DOOR REAR GUIDE SEAL 
    1. Disengage the 3 clips and claw to remove the rear door rear guide seal.
      GTY424410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Put protective tape around the rear door panel.
      GTY427150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a screwdriver with its tip wrapped with protective tape, disengage the claw and open the cover.
      GTY423543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Remove the 3 screws.
      GTY450529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 9 clips and claw, and remove the rear door trim board sub-assembly as shown in the illustration.
      GTY424391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. w/ Illumination:
      1. Disconnect the connector.
    6. Disconnect the rear door lock remote control cable assembly and rear door inside locking cable assembly.
      GTY450530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the 2 claws and guide, and remove the rear door inside handle sub-assembly.
      GTY450531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  11. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP 
    1. Disengage the 7 claws and remove the rear door inner glass weatherstrip as shown in the illustration.
      GTY424398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE REAR CURTAIN SUB-ASSEMBLY (w/ Rear Door Sunshade) 
    1. Remove the 7 screws.
      GTY424378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 3 guides and remove the rear curtain sub-assembly.
  13. REMOVE REAR DOOR SERVICE HOLE COVER 
    1. Disconnect the 2 connectors.
      GTY424379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps and remove the rear door service hole cover.

      HINT: 

      Remove any remaining butyl tape from the rear door panel.

  14. REMOVE REAR DOOR PANEL PROTECTOR 
    1. Disengage the clip, claw and 2 guides, and remove the rear door panel protector.
      GTY450527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts and rear door check assembly.
      GTY444063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  16. REMOVE REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 20 clips and remove the rear door weatherstrip.
      GTY424386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REAR DOOR GLASS RUN 
    1. Remove the rear door glass run.
      GTY424385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. Remove the 2 bolts and nut.
      GTY427355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      Screw
    2. Remove the screw and rear door window division bar sub-assembly.
  19. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. Remove the grommet.
      GTY450528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the cable to the negative (-) auxiliary battery terminal.
    3. Connect the rear power window regulator switch assembly and move the rear door glass sub-assembly so that the door glass bolts can be seen.
    4. Disconnect the cable from the negative (-) auxiliary battery terminal.
    5. Disconnect the rear power window regulator switch assembly.
    6. Remove the 2 bolts.
      GTY424390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the rear door glass sub-assembly.

    7. Remove the rear door glass sub-assembly as shown in the illustration.
      NOTE:

      Do not damage the rear door glass sub-assembly.

      GTY424388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. 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.

      GTY451867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporary Bolt
    2. Remove the 5 bolts.
    3. Remove the rear door window regulator assembly.
    4. Remove the temporary bolt from the rear door window regulator assembly.
  21. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    1. Using a T25 "TORX" socket wrench, remove the 3 screws and power window regulator motor assembly.
      GTY424376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the 3 screws.
      GTY425721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Release Plate
    2. Move the rear door lock with motor assembly downward to disconnect it from the release plate of the rear door outside handle frame sub-assembly and remove the rear door lock with motor assembly.
    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.
        GTY424510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 2 claws as shown in the illustration.
      GTY424511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear door lock remote control cable assembly as shown in the illustration.
      GTY424509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Remove the rear door inside locking cable assembly as shown in the illustration.
      GTY424507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE REAR DOOR OUTSIDE HANDLE COVER 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY424505Courtesy 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.
  26. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Pull and hold the release plate of the rear door outside handle frame sub-assembly as shown in the illustration.
      GTY424533Courtesy 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 it is pulled and held.

    2. Remove the rear door outside handle assembly as shown in the illustration.
      GTY424534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws and remove the rear door front outside handle pad.
      GTY450560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws and remove the rear door rear outside handle pad.
      GTY424536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY430913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Inside
      *B Outside
    2. Slide the rear door outside handle frame sub-assembly to disengage the claw, and then remove it.
  30. REMOVE REAR DOOR CUSHION 
    1. Remove the 2 bolts.
      GTY453347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
    2. Disengage the 2 guides and remove the rear door cushion.
  31. REMOVE REAR DOOR FRAME GARNISH (w/o Rear Door Sunshade) 
    1. Disengage the 3 claws and remove the rear door frame garnish.
      GTY424531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REAR DOOR FRAME GARNISH (w/ Rear Door Sunshade) 
    1. Disengage the 3 claws and remove the rear door frame garnish.
      GTY450559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE REAR DOOR PANEL CUSHION 
    1. Disengage the 2 claws and remove the 2 rear door panel cushions.
      GTY450557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE REAR DOOR VENT SEAL 
    1. Remove the rear door vent seal.
      GTY430569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  35. REMOVE REAR DOOR LOWER HOLE COVER 
    1. Remove the rear door lower hole cover.
      GTY442295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 15

  37. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  38. REMOVE REAR DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 4

  39. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 5

  40. REMOVE REAR DOOR REAR UPPER OUTSIDE MOULDING 

    Refer to PROCEDURE - Step 6

  41. REMOVE REAR DOOR NO. 3 WEATHERSTRIP 
    1. Disengage the claw and remove the rear door No. 3 weatherstrip.
      GTY448873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  42. REMOVE FRONT INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 17

  43. REMOVE REAR INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 18

  44. REMOVE UPPER INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 19

  45. REMOVE REAR DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  46. REMOVE NO. 1 OUTSIDE MOULDING RETAINER 
    1. Disengage the 2 clips as shown in the illustration.
      GTY424525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clips and remove the 2 No. 1 outside moulding retainers.
      GTY424521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE NO. 1 OUTSIDE MOULDING RETAINER 
    1. Remove the screw.
      GTY424522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clip and remove the No. 1 outside moulding retainer.
      GTY450556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE REAR DOOR NO. 2 WEATHERSTRIP 
    1. Using a clip remover, disengage the 6 clips and remove the rear door No. 2 weatherstrip.
      GTY450558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  50. REMOVE REAR DOOR UPPER OUTSIDE MOULDING PAD 

    Refer to PROCEDURE - Step 3

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