REAR DOOR DISASSEMBLY

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.


  1. PRECAUTION

    Note

    After turning the ignition 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 Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A01HXPB

      Using a moulding remover, disengage the 3 claws and remove the rear door inside handle bezel plug as shown in the illustration.

  4. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH REAR DOOR ARMREST BASE PANEL


    1. A01HZD8

      Using a moulding remover, disengage the 2 clips, 5 claws and 3 guides as shown in the illustration.

    2. Disconnect the connector and remove the rear power window regulator switch assembly with rear door armrest base panel.

  5. REMOVE REAR ARMREST ASSEMBLY


    1. A01HYVF

      Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the rear armrest assembly.

  6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A01HZ67E01
      Text in Illustration
      *a Protective Tape

      Apply protective tape to the rear door panel.

    2. A01I0EO

      Remove the 3 screws.

    3. Using a clip remover, disengage the 8 clips.

    4. A01I07HE01
      Text in Illustration
      *1 Rear Door Inner Glass Weatherstrip
      *a Reference Boss

      Pull out the rear door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.

    5. Disengage the reference boss from the rear door panel.

    6. Raise the rear door trim board sub-assembly to remove the rear door trim board sub-assembly together with the rear door inner glass weatherstrip.

    7. A01I06T

      Disconnect the rear door lock remote control cable assembly and rear door inside locking cable assembly.

    8. A01HXYAE02
      Text in Illustration
      *a Screwdriver

      Using a screwdriver, disengage the claw and remove the No. 1 door scuff plate clamp from the rear door trim board sub-assembly as shown in the illustration.

  7. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01HYWD

      Disengage the 2 claws and guide, and remove the rear door inside handle sub-assembly.

  8. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP


    1. A01HY2SE02
      Text in Illustration
      *a Screwdriver

      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.

  9. REMOVE REAR DOOR SERVICE HOLE COVER


    1. A01HZPP

      Disconnect the connector.

    2. Pass the rear door lock remote control cable assembly, rear door inside locking cable assembly and each connector through the rear door service hole cover.

    3. Remove the rear door service hole cover.

      Tech Tips

      Remove any remaining butyl tape from the rear door panel.

  10. REMOVE REAR DOOR CHECK ASSEMBLY


    1. A01HZZ0

      Remove the bolt and 2 nuts, and rear door check assembly.

  11. REMOVE REAR DOOR WEATHERSTRIP


    1. A01I1OC

      Using a clip remover, disengage the 20 clips and remove the rear door weatherstrip.

  12. REMOVE REAR DOOR GLASS RUN


    1. A01HYSQ

      Remove the rear door glass run.

  13. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. A01I169

      Remove the 2 bolts and screw, and rear door lower window frame sub-assembly.

      Note

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

  14. REMOVE REAR DOOR QUARTER WINDOW GLASS


    1. A01HXYW

      Remove the rear door quarter window glass with the rear door quarter window weatherstrip as shown in the illustration.

    2. Remove the rear door quarter window glass from the rear door quarter window weatherstrip.

  15. REMOVE REAR DOOR GLASS SUB-ASSEMBLY


    1. A01HYZW

      Remove the rear door glass sub-assembly from the rear door window regulator sub-assembly as shown in the illustration.

      Note

      Do not damage the rear door glass sub-assembly.

  16. REMOVE REAR DOOR FRAME GARNISH


    1. A01I0AD

      Disengage the clip and remove the rear door frame garnish.

      Tech Tips

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

  17. REMOVE REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY


    1. A01HZZQ

      Remove the 4 screws.

    2. Disengage the guide and remove the rear door inside panel reinforce sub-assembly.

  18. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY


    1. A01HZM1E03
      Text in Illustration
      *a Temporary Bolt

      Disconnect the connector.

    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 3 bolts.

    4. Remove the rear door window regulator assembly.

    5. Remove the temporary bolt from the rear door window regulator assembly.

  19. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY


    1. A01HXED

      Using a T25 "TORX" socket wrench, remove the 3 screws and rear power window regulator motor assembly.

  20. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY


    1. A01HXFWE02
      Text in Illustration
      *a Release Plate

      Using a T30 "TORX" socket wrench, remove the 3 screws.

    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. A01HZTR

        Remove the door lock wiring harness seal from the rear door lock with motor assembly.

  21. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A01I0X6

      Using a screwdriver, disengage the claw as shown in the illustration.

    2. A01I05X

      Remove the rear door lock remote control cable assembly.

  22. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A01HZZU

      Using a screwdriver, disengage the 3 claws as shown in the illustration.

    2. A01HZG4

      Remove the rear door inside locking cable assembly.

  23. REMOVE REAR DOOR OUTSIDE HANDLE COVER


    1. A01I1S5

      Using a T30 "TORX" socket wrench, loosen the screw.

      Tech Tips

      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.

  24. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A01I17O

      Pull and hold the release plate of the rear door outside handle frame sub-assembly as shown in the illustration.

      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. A01I0WV

      Remove the rear door outside handle assembly as shown in the illustration.

  25. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A01HZRM

      Disengage the 3 claws and remove the rear door front outside handle pad.

  26. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A01I1JV

      Disengage the 2 claws and remove the rear door rear outside handle pad.

  27. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. A01HZ5ZE01
      Text in Illustration
      *1 Door Handle Nut
      *a Outside
      *b Inside

      Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

    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.

  28. REMOVE REAR DOOR NO. 2 WEATHERSTRIP


    1. A01I0R6

      Using a clip remover, disengage the 5 clips and remove the rear door No. 2 weatherstrip.

  29. REMOVE REAR DOOR PANEL CUSHION


    1. A01HYSU

      Disengage the 2 claws and remove the 2 rear door panel cushions.

  30. REMOVE REAR DOOR BELT MOULDING ASSEMBLY


    1. A01HXPW

      Apply protective tape around the rear door belt moulding assembly as shown in the illustration.

      Text in Illustration
      A01I1AA Protective Tape
    2. A01I15R

      Using a screwdriver with its tip wrapped with protective tape, disengage the 6 claws to remove the rear door belt moulding assembly as shown in the illustration.

      Text in Illustration
      A01I1AA Protective Tape

  31. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING

    Tech Tips

    When removing the rear door front window frame moulding, heat the vehicle body and rear door front window frame moulding using a heat light.

    Heating Temperature
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Rear Door Front Window Frame Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or rear door front window frame moulding excessively.


    1. Using a heat light, heat the rear door front window frame moulding.

    2. A01I10AE01
      Text in Illustration
      *a Caulking Sponge
      A01I1AA Double-sided Tape

      Using a moulding remover, disengage the clip and guide, and separate the double-sided tape to remove the rear door front window frame moulding.

  32. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING


    1. Insert a 4.0 mm (0.157 in.) drill bit into a drill.

    2. A01HXYBE01

      Tape the 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

      Standard Measurement
      Area Measurement
      A 5.0 mm (0.197 in.)

      Note

      Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

    3. Lightly press the drill bit against the rivets to drill off the rivet flanges, and remove the 4 rivets.

      Note


      • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.

      • Prying the rivets with the drill may damage the rivet installation holes or drill bit.

      • Be careful of the drilled rivets, as they may be hot.

    4. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas.

    5. Disengage the guide and remove the rear door upper window frame moulding from the door frame.

  33. REMOVE REAR DOOR REAR WINDOW FRAME MOULDING


    1. Insert a 4.0 mm (0.157 in.) drill bit into a drill.

    2. A01HZNWE01

      Tape the 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

      Standard Measurement
      Area Measurement
      A 5.0 mm (0.197 in.)

      Note

      Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

    3. Lightly press the drill bit against the rivets to drill off the rivet flanges, and remove the 4 rivets.

      Note


      • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.

      • Prying the rivets with the drill may damage the rivet installation holes or drill bit.

      • Be careful of the drilled rivets, as they may be hot.

    4. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas.

    5. Remove the rear door rear window frame moulding.

  34. REMOVE REAR DOOR OUTSIDE STRIPE


    1. Using a heat light, heat the rear door outside stripe and vehicle body.

      Heating Temperature
      Item Temperature
      Vehicle Body and Rear Door Outside Stripe 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A01HXKN

      Pull back on one of the ends of the rear door outside stripe to remove it.

      Tech Tips

      When pulling on the rear door outside stripe, pull it parallel to the body.

  35. REMOVE REAR DOOR LOWER OUTSIDE STRIPE


    1. Using a heat light, heat the rear door lower outside stripe and vehicle body.

      Heating Temperature
      Item Temperature
      Vehicle Body and Rear Door Lower Outside Stripe 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A01HZ4C

      Pull back on one of the ends of the rear door lower outside stripe to remove it.

      Tech Tips

      When pulling on the rear door lower outside stripe, pull it parallel to the body.

  36. REMOVE NO. 2 BLACK OUT TAPE


    1. Using a heat light, heat the No. 2 black out tape and vehicle body.

      Heating Temperature
      Item Temperature
      Vehicle Body and No. 2 Black Out Tape 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A01I0OE

      Pull back on one of the ends of the No. 2 black out tape to remove it.

      Tech Tips

      When pulling on the No. 2 black out tape, pull it parallel to the body.