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Home >> Toyota >> 2020 >> Mirai >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Doors / Hatch) - Service Information >> Rear Door >> Disassembly [11/2018 - ] >> Procedure

Disassembly [11/2018 - ]: Procedure

  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 INITIALIZATION [11/2018 - ]

  2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 2

  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

  4. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a moulding remover A, disengage the claws to remove the rear door inside handle bezel plug.
      GTY545340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  5. REMOVE REAR DOOR ARMREST COVER 
    1. Using a moulding remover A, disengage the claw and guides to remove the rear door armrest cover.
      GTY560324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  6. REMOVE NO. 1 REAR DOOR STIFFENER CUSHION 
    1. Remove the No. 1 rear door stiffener cushion.
      GTY595019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 3 screws.
      GTY595018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clips as shown in the illustration.
      GTY542662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hands Here
      Remove in this Direction
    3. Disengage the clamps to remove rear door trim board sub-assembly as shown in the illustration.
      GTY599851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hands Here
      Remove in this Direction
    4. Disconnect the connector.
      GTY594961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the guides.
      GTY555467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Door Inside Locking Cable Assembly
      *2 Rear Door Lock Remote Control Cable Assembly
    6. Disconnect the rear door lock remote control cable assembly and rear door inside locking cable assembly to remove the rear door trim board sub-assembly.
  9. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the claws to remove the rear door inside handle sub-assembly.
      GTY602855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      Remove in this Direction
  10. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 6

  11. REMOVE REAR DOOR WIRE 
    1. Using a clip remover, disengage the clamp to remove the rear door wire.
      GTY594969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE REAR DOOR GLASS INNER WEATHERSTRIP 
    1. Remove the rear door glass inner weatherstrip as shown in the illustration.
      GTY576493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  13. REMOVE REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  14. REMOVE REAR DOOR SERVICE HOLE COVER 
    1. Using a clip remover, disengage the clamps to separate the wire harness.
      GTY583931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Butyl Tape
    2. Remove the rear door service hole cover.
      NOTE:

      Remove any remaining butyl tape from the rear door panel.

  15. REMOVE REAR DOOR GLASS RUN 
    1. Remove the rear door glass run as shown in the illustration.
      GTY597090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  16. REMOVE REAR DOOR FRAME GARNISH 
    1. Disengage the guides to remove the rear door frame garnish as shown in the illustration.
      GTY544007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  17. REMOVE REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the screw.
      GTY594957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and rear door window rear lower frame sub-assembly.
  18. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. Connect the rear power window regulator switch assembly.
    2. Connect the cable to the auxiliary battery negative (-) terminal.
    3. More the rear door window regulator sub-assembly LH so that the door glass bolts can be seen.
    4. Disconnect the cable from the auxiliary battery negative (-) terminal.
      WARNING:
      • Wait at least 90 seconds after disconnecting the cable from the auxiliary battery negative (-) terminal to disable the SRS system.
        GTY581108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • If the airbag deploys for any reason, it may cause a serious accident.
      NOTE:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

      Refer to INITIALIZATION [11/2018 - ]

    5. Disconnect the rear power window regulator switch assembly.
    6. Remove the 2 bolts.
      GTY594956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    7. Remove the rear door glass sub-assembly as shown in the illustration.
      GTY588341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
      NOTE:

      Do not damage the rear door glass sub-assembly.

  19. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Disconnect the connector.
      GTY610052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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 sub-assembly may fall and cause damage.

    3. Remove the 5 bolts and rear door window regulator sub-assembly.
    4. Remove the temporary bolt from the rear door window regulator sub-assembly.
  20. REMOVE REAR DOOR CUSHION 
    1. Remove the 2 bolts.
      GTY593879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-side Tape
    2. Remove the double-side tape and rear door cushion.
      NOTE:

      Remove any remaining double-side tape from the rear door panel.

  21. REMOVE REAR DOOR REAR GUIDE SEAL 
    1. Raise up the rear door weatherstrip and then remove the screw.
    2. Remove the 3 screws.
      GTY597998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Remove the rear door rear guide seal as shown in the illustration.
  22. REMOVE REAR DOOR LOCK ASSEMBLY 

    Refer to PROCEDURE - Step 14

  23. REMOVE REAR DOOR OUTSIDE HANDLE COVER 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY546655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Disengage the claws to remove the rear door outside handle cover as shown in the illustration.
  24. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Remove the rear door outside handle assembly as shown in the illustration.
      GTY600962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  25. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the claws to remove the rear door front outside handle pad.
      GTY561359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  26. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the claws to remove the rear door rear outside handle pad.
      GTY568210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  27. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY538751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      *b Guide
      Remove in this Direction
    2. Disengage the grommet and guides to remove the rear door outside handle frame sub-assembly as shown in the illustration.
  28. REMOVE REAR DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts and the rear door check assembly.
      GTY594977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, remove the 2 clips.
      GTY559065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-side Tape
    2. Using a clip remover, disengage the clips.
    3. Remove the double-side tape and rear door weatherstrip.
      NOTE:

      Remove any remaining double-side tape from the rear door panel.

  30. REMOVE REAR DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 15

  31. REMOVE REAR DOOR WINDOW FRAME FRONT MOULDING 

    Refer to PROCEDURE - Step 7

  32. REMOVE REAR DOOR WINDOW FRAME UPPER MOULDING 

    Refer to PROCEDURE - Step 8

  33. REMOVE REAR DOOR WINDOW FRAME REAR MOULDING 

    Refer to PROCEDURE - Step 9

  34. REMOVE REAR DOOR LOWER OUTSIDE STRIPE 

    Refer to PROCEDURE - Step 9

  35. REMOVE REAR DOOR OUTSIDE STRIPE 

    Refer to PROCEDURE - Step 10

  36. REMOVE REAR DOOR UPPER OUTSIDE STRIPE 

    Refer to PROCEDURE - Step 11

  37. REMOVE NO. 2 REAR DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the clips to remove the No. 2 rear door weatherstrip.
      GTY594932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE NO. 3 REAR DOOR WEATHERSTRIP 
    1. Remove the double-side tape.
      GTY573096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-side Tape
      NOTE:

      Remove any remaining double-side tape from the rear door panel.

    2. Disengage the guide to remove the No. 3 rear door weatherstrip.
  39. REMOVE REAR DOOR PANEL CUSHION 
    1. Disengage the claw to remove the rear door panel cushion.
      GTY610125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE HOLE PLUG 
    1. Remove the 2 hole plugs.
      GTY594929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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