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Disassembly [03/2023 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [12/2022 - ]
  2. REMOVE BATTERY SERVICE HOLE COVER ASSEMBLY (for M20A-FXS) 
    Refer to PROCEDURE - Step 2
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    1. for M20A-FXS:

      Refer to PROCEDURE - Step 3

    2. for 2ZR-FXE:

      Refer to PROCEDURE - Step 2

  4. REMOVE REAR DOOR TRIM UPPER COVER 
    1. GTY1138764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a moulding remover, disengage the 3 claws to remove the rear door trim upper cover.
  5. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL 
    1. GTY1145576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Apply protective tape to the rear door trim board sub-assembly as shown in the illustration.
      2. Using a moulding remover, disengage the clip and 6 claws.
      3. Disconnect the connector to remove the rear power window regulator switch assembly with rear door armrest base panel.
  6. REMOVE REAR DOOR REAR FRAME BRACKET 
    1. GTY1156338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY 
    1. GTY1150940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a moulding remover, disengage the 2 claws as shown in the illustration.
    2. GTY1159140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 4 screws.
    3. GTY1156139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here Remove in this Direction
      1. Apply protective tape to the rear door panel as shown in the illustration.
      2. Disengage the 8 clips as shown in the illustration.
      3. Disengage the 4 claws and guide as shown in the illustration.
      4. Disconnect the rear door lock open lever remote control cable and rear door inside lock/unlock knob locking cable as shown in the illustration to remove the rear door trim board sub-assembly.
  8. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. GTY1143397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  9. REMOVE REAR DOOR FRAME GARNISH 
    1. GTY1145117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a clip remover with its tip wrapped with protective tape, disengage the clip.
      2. Disengage the 3 claws to remove the rear door frame garnish.
  10. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP 
    1. GTY1147544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  11. REMOVE NO. 1 REAR DOOR VENT SEAL 
    1. GTY1154889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  12. REMOVE REAR DOOR PANEL PROTECTOR 
    1. GTY1159962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  13. REMOVE REAR SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  14. REMOVE DOOR LOCK RELEASE MOTOR ASSEMBLY 
    1. GTY1156363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR DOOR SERVICE HOLE COVER 
    1. GTY1150754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the clamp.
      2. Remove the rear door service hole cover.
        NOTE:

        Remove any remaining butyl tape from the door.

  16. REMOVE REAR DOOR TRIM BRACKET 
    1. GTY1156365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE REAR DOOR GLASS RUN 
    1. GTY1156367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY 
    1. GTY1154472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Lift up the rear door weatherstrip as shown in the illustration.
      2. Remove the 2 bolts, screw and rear door window division bar sub-assembly.
  19. REMOVE REAR DOOR QUARTER WINDOW GLASS 
    1. GTY1152614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  20. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP 
    1. GTY1139321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE HOLE PLUG 
    1. GTY1139318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE REAR DOOR GLASS SUB-ASSEMBLY 
    1. GTY1144303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the rear power window regulator switch assembly.
      2. Connect the cable to the negative (-) auxiliary battery terminal and turn the ignition switch to ON.
      3. Move the rear door glass sub-assembly so that the door glass bolts can be seen and turn the ignition switch off.
    2. GTY1151364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Disconnect the cable from the negative (-) auxiliary battery terminal.
      2. Disconnect the rear power window regulator switch assembly.
      3. Remove the 2 bolts.
        NOTE:

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

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

        Do not damage the rear door glass sub-assembly.

  23. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY 
    1. GTY1156358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE REAR DOOR BELT MOULDING ASSEMBLY 
    Refer to PROCEDURE - Step 2
  25. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY 
    1. GTY1146496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1) Remove in this Direction (2)
    2. When reusing the rear door outside handle assembly:
      GTY1274718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 2 REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. GTY1156359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY WITH CABLE 
    Refer to PROCEDURE - Step 10
  28. REMOVE DOOR LOCK WIRING HARNESS SEAL 
    Refer to PROCEDURE - Step 11
  29. REMOVE REAR DOOR CHECK ASSEMBLY 
    1. GTY1156361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE REAR DOOR WEATHERSTRIP 
    1. GTY1148115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Double-sided Tape - -
      1. Using a clip remover with its tip wrapped with protective tape, disengage the 3 clips.
      2. Disengage the 24 clips and separate the double-sided tape to remove the rear door weatherstrip.
  31. REMOVE DOOR WINDOW FRAME MOULDING CLIP 
    1. GTY1156392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REAR DOOR PANEL CUSHION 
    1. GTY1156393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE REAR DOOR WINDOW FRAME FRONT MOULDING 
    Refer to PROCEDURE - Step 4
  34. REMOVE REAR DOOR WINDOW FRAME UPPER MOULDING 
    Refer to PROCEDURE - Step 5
  35. REMOVE DOOR DUST PROOF SEAL 
    1. GTY1156394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE REAR DOOR SILENCER PAD 
    1. GTY1139326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE REAR DOOR FRONT OUTSIDE SEAL 
    1. GTY1156396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE REAR DOOR REAR BELT SEAL 
    1. GTY1156397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE BLE DOOR DIGITAL KEY RECEIVER ASSEMBLY (for Rear Door) 
    Refer to PROCEDURE - Step 7
  40. REMOVE REAR DOOR REAR PROTECTOR ASSEMBLY 
    NOTE:

    When removing the rear door rear protector assembly, if the protection tape is difficult to remove, heat the adhesive of the rear door rear protector assembly using a heat light.
    HEATING TEMPERATURE

    Area Temperature Area Temperature
    Rear Door Rear Protector Assembly 40 to 60 °C (104 to 140 °F) - -
    WARNING:
    • Do not touch the heat light and heated parts.
    • Touching the heat light may result in burns.
    • Touching heated parts for a long time may result in burns.
    GTY749838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Heated Part
    *b Heat Light
    NOTE:

    Do not heat the rear door rear protector assembly excessively.

    1. GTY1143328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protection Tape - -
      1. Apply protective tape around the rear door rear protector assembly.
      2. Heat the adhesive of the rear door rear protector assembly using a heat light.
      3. Disconnect the protection tape to remove the rear door rear protector assembly.
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