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 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 Click here.

  2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER


    1. A01I3Q8

      Disengage the claw to remove the luggage trim service hole cover.

  3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  4. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A01I52X

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

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


    1. A01I63U

      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.

  6. REMOVE REAR ARMREST ASSEMBLY


    1. A01I4OW

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

  7. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A01I5SVE02
      Text in Illustration
      *a Protective Tape

      Apply protective tape to the rear door panel.

    2. A01I31I

      Remove the 3 screws.

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

    4. A01I3NYE02
      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. A01I2MY

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

    8. A01I3L0E03
      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.

  8. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01I2UW

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

  9. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP


    1. A01I601E03
      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.

  10. REMOVE REAR DOOR SERVICE HOLE COVER


    1. A01I57K

      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.

  11. REMOVE REAR DOOR CHECK ASSEMBLY


    1. A01I4VR

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

  12. REMOVE REAR DOOR WEATHERSTRIP


    1. A01I2FH

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

  13. REMOVE REAR DOOR GLASS RUN


    1. A01I3EG

      Remove the rear door glass run.

  14. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. A01I4X3

      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.

  15. REMOVE REAR DOOR QUARTER WINDOW GLASS


    1. A01I5GC

      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.

  16. REMOVE REAR DOOR GLASS SUB-ASSEMBLY


    1. A01I28W

      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.

  17. REMOVE REAR DOOR FRAME GARNISH


    1. A01I3RM

      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.

  18. REMOVE REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY


    1. A01I4V3

      Remove the 4 screws.

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

  19. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY


    1. A01I52HE05
      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.

  20. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY


    1. A01I35Y

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

  21. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY


    1. A01I3GWE03
      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. A01I39D

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

  22. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A01I4J4

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

    2. A01I3Y4

      Remove the rear door lock remote control cable assembly.

  23. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A01I3NW

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

    2. A01I2V4

      Remove the rear door inside locking cable assembly.

  24. REMOVE REAR DOOR OUTSIDE HANDLE COVER


    1. A01I3WL

      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.

  25. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A01I5E7

      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. A01I4HD

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

  26. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A01I5H8

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

  27. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A01I3X9

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

  28. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. A01I48FE01
      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.

  29. REMOVE REAR DOOR NO. 2 WEATHERSTRIP


    1. A01I39G

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

  30. REMOVE REAR DOOR PANEL CUSHION


    1. A01I3VJ

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

  31. REMOVE REAR DOOR BELT MOULDING ASSEMBLY


    1. A01I4WB

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

      Text in Illustration
      A01I3GM Protective Tape
    2. A01I5HQ

      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
      A01I3GM Protective Tape
  32. 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. A01I3KFE01
      Text in Illustration
      *a Caulking Sponge
      A01I3GM 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.

  33. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING


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

    2. A01I2DAE01

      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.

  34. REMOVE REAR DOOR REAR WINDOW FRAME MOULDING


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

    2. A01I4Q7E01

      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.

  35. 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. A01I41H

      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.

  36. 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. A01I5DT

      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.

  37. 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. A01I5MP

      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.