Rear Door: Disassembly

1. Using a screwdriver, remove the cover.

   HINT:

   Tape the screwdriver tip before use.

2. Remove the screw.
3. Using a screwdriver, remove the inside handle bezel as shown in Fig 1 .

   HINT:

   Tape the screwdriver tip before use.

Fig 1: Removing Inside Handle Bezel

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the upper armrest base panel with power window switch.

   HINT:

   Tape the screwdriver tip before use.

2. Disconnect the connector.
3. Remove the power window switch from the upper armrest base panel.

Fig 2: Removing Upper Armrest Base Panel

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a screwdriver, remove the rear guide bracket garnish.

HINT:

Tape the screwdriver tip before use.

Fig 3: Removing Rear Guide Bracket Garnish

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 screws and 2 clips.
2. Pull the trim upward to remove it.
   Fig 4: Removing Door Trim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, remove the rear door inner weatherstrip.
4. Remove the 13 screws and rear door armrest.
5. Remove the 7 screws and rear door trim pocket.

1. Remove the screw.
2. Slide the inside handle backward to remove it.
   Fig 5: Removing Rear Door Armrest And Rear Door Trim Pocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the 2 cables from the inside handle as shown in Fig 6 .

1. Disconnect the 2 control cables from the link clamp.
2. Using a clip remover, remove the grommets and link clamp.
3. Remove the service hole cover.
   NOTE: Do not tear the cover.

   HINT:

   At the time of reassembly, please refer to the following item. Bring out the 2 control cables and wire harness through the service hole cover.

1. Remove the screw from the door check.
2. Using a clip remover, remove the rear door weatherstrip.
3. Reinstall the screw to the door check.

   Torque: 25 N.m (260 Kgf.cm, 19 ft.lbf) 

Fig 7: Removing Service Hole Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply protective tape to the outer surface as shown in Fig 8 , to keep the surface from being scratched.
2. Using a moulding remover, remove the rear door belt moulding.

Fig 8: Applying Protective Tape To Outer Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a drill of less than 03.2 mm (0.126 in.), drill out the 2 rivet heads.

   HINT:

   Gently and vertically put the drill to the rivet, and cut the rivet flanges.

   CAUTION: Take care as the cut rivet is hot.
   NOTE: Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
2. Using a clip remover, remove the clip.
3. Remove the rear door outside lower moulding.
4. Using a vacuum cleaner, remove the drilled rivets and their dust from the inside of door panel.

   HINT:

   At the time of reassembly, please refer to the following item

   Using an air riveter with nose piece No. 1 or hand riveter with nose piece No. 1, install the 3 rivets to the front door outside lower moulding.

   Fig 9: Drilling Out Rivet Heads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • At the time of reassembly, please refer to the following items.
   • Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
     Fig 10: Precaution While Installing Rivets (1 Of 3)

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly. 
     Fig 11: Precaution While Installing Rivets (2 Of 3)

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • Install the rivet while attaching materials, as they are not tightened firmly. 
     Fig 12: Precaution While Installing Rivets (3 Of 3)

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt, nut, 3 screws and rear door window guide with guide piece plate.
2. Remove the guide piece plate from the rear door window guide.

1. Open the door glass until the bolts appear in the service hole.
2. Remove the 2 bolts.

   Torque: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

   NOTE: Be careful not to drop the door glass.
3. Pull the door glass upward to remove it.

1. Disconnect the connector, then remove the 4 nuts and window regulator assembly.

   Torque: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

   HINT:

   Remove the window regulator assembly through the service hole.

2. Using a torx driver, remove the 3 torx screws and window regulator motor from the window regulator guide assembly.

   HINT:

   • At the time of reassembly, please refer to the following items.
   • Apply MP grease to the glass guide and rollers of window regulator assembly.
   • After installing the window regulator assembly, window regulator assembly need to be re-initialized.

     Refer to ADJUSTMENT .

1. Disconnect the control link from the outside handle.
2. Disconnect the connector.
3. Remove the 3 torx screws and door lock.

   Torque: 

   Bolt: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

   Screw: 4.9 N.m (50 Kgf.cm, 43 in.lbf) 

   HINT:

   Remove the door lock through the service hole.

   HINT:

   At the time of reassembly, please refer to the following item.

   Apply adhesive to 3 screws.

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

4. Remove the 2 screws and door lock protector from the door lock.
   Fig 13: Applying MP Grease To Glass Guide And Rollers Of Window Regulator Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   At the time of reassembly, please refer to the following item.

   Apply MP grease to the sliding and rotating parts of the door lock.

Remove the 2 bolts and outside handle.

Torque: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

Fig 14: Applying MP Grease To Sliding And Rotating Parts Of Door Lock

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002