REAR DOOR (for TMC, TMMR Made) DISASSEMBLY

Tech Tips


  • Use the same procedure for both the RH and LH sides.

  • The procedure described below 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. B000NDR

      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. B000I33

      Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

    2. w/o Seat Heater System:


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

    3. w/ Seat Heater System:


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

  5. REMOVE REAR ARMREST ASSEMBLY


    1. B000LSK

      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. B000JX3E01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the rear door panel.

    2. B000I2D

      Remove the 3 screws.

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

    4. B000JHIE01
      Text in Illustration
      *1 Reference Boss
      *2 Rear Door Inner Glass Weatherstrip

      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. B000ITM

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

    8. Disconnect the connector.

    9. B000HNNE01
      Text in Illustration
      *1 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. B000J2V

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

  8. REMOVE REAR DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY


    1. B000MD0

      Disengage the 3 clamps and claw, and remove the rear door inside handle illumination light assembly.

  9. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP


    1. B000ND9E01
      Text in Illustration
      *1 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 CURTAIN SUB-ASSEMBLY (w/ Rear Door Sunshade)


    1. B000I83

      Remove the 9 screws and rear curtain sub-assembly.

  11. REMOVE REAR DOOR SERVICE HOLE COVER


    1. B000IV7

      Disconnect the connector and remove the rear door service hole cover.

      Tech Tips

      Remove any remaining butyl tape from the door.

  12. REMOVE REAR DOOR CHECK ASSEMBLY


    1. B000JM1

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

  13. REMOVE REAR DOOR WEATHERSTRIP


    1. B000L9C

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

  14. REMOVE REAR DOOR GLASS RUN


    1. B000MBM

      Remove the rear door glass run.

  15. REMOVE REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY


    1. B000MZL

      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.

  16. REMOVE REAR DOOR QUARTER WINDOW GLASS


    1. B000JAB

      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.

  17. REMOVE REAR DOOR GLASS SUB-ASSEMBLY


    1. B000JWW

      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 door glass.

  18. REMOVE REAR DOOR GLASS CHANNEL SUB-ASSEMBLY


    1. B000HJ4E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the rear door glass channel sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  19. REMOVE REAR DOOR GLASS CHANNEL FILLER


    1. Remove the rear door glass channel filler.

  20. REMOVE REAR DOOR FRAME GARNISH


    1. B000LBE

      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.

  21. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY


    1. B000KAVE01
      Text in Illustration
      *1 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.

  22. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY


    1. B000H7L

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

  23. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY


    1. B000JB0E01
      Text in Illustration
      *1 Release Plate

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

    2. Move the rear door lock with motor assembly downward and pull the release plate out of the rear door outside handle frame.

    3. When reusing the rear door lock with motor assembly:


      1. B000H1Z

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

  24. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B000JDX

      Using a screwdriver, disengage the claw.

    2. B000N8Y

      Remove the rear door lock remote control cable assembly.

  25. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B000K16

      Using a screwdriver, disengage the 3 claws.

    2. B000JET

      Remove the rear door inside locking cable assembly.

  26. REMOVE REAR DOOR OUTSIDE HANDLE COVER


    1. B000MLT

      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.

  27. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. B000IBX

      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 the release plate of the rear door outside handle frame sub-assembly is pulled and held.

    2. B000KOL

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

  28. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. B000HOL

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

  29. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD


    1. B000IYY

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

  30. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. B000IHYE01
      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.

  31. REMOVE CURTAIN HOOK (w/ Rear Door Sunshade)


    1. B000IJLE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, push out the pin as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B000N9RE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with the tip wrapped with protective tape, disengage the pin.

      Tech Tips

      Tape the screwdriver tip before use.

    3. B000NPU

      Disengage the 2 claws and remove the 2 curtain hooks as shown in the illustration.

  32. REMOVE REAR DOOR NO. 2 WEATHERSTRIP


    1. B000IZA

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

  33. REMOVE REAR DOOR PANEL CUSHION


    1. B000MXR

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

  34. REMOVE REAR DOOR BELT MOULDING ASSEMBLY


    1. B000KAGE01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the rear door belt moulding assembly.

    2. B000NRSE01
      Text in Illustration
      *1 Protective Tape

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

  35. 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)
    Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or moulding excessively.


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

    2. B000MHFE01
      Text in Illustration
      *1 Double-sided Tape
      *2 Caulking Sponge

      Using a moulding remover, disengage the clip and remove the rear door front window frame moulding.

  36. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING


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

    2. B000LDWE01

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

      Area Dimension
      A 5.0 mm

      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 6 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.

  37. 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. B000HDH

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

      Tech Tips

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

  38. 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. B000J5V

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

      Tech Tips

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