REAR DOOR 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 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 REAR NO. 3 FLOOR BOARD


    1. Remove the rear No. 3 floor board.

  3. REMOVE DECK FLOOR BOX RH


    1. Fold back the rear No. 2 floor board.

    2. Remove the deck floor box RH Click here.

  4. REMOVE REAR NO. 3 FLOOR BOARD UPPER PLATE


    1. A0040W5

      Disengage the 2 claws and remove the rear No. 3 floor board upper plate.

  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  6. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A00401M

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

  7. REMOVE DOOR ASSIST GRIP COVER


    1. A003ZX2

      Using a moulding remover, disengage the 6 claws, 2 clips and 3 guides, and remove the door assist grip cover.

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


    1. A0041MN

      Disengage the 7 claws and 2 guides.

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

  9. REMOVE REAR DOOR ARMREST COVER


    1. A0041EU

      Remove the rear door armrest cover.

  10. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A0043YGE02
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the rear door panel.

    2. A00429Z

      Remove the 2 screws.

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

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

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

    6. A00437P

      Disengage the 2 claws and disconnect the rear door inside handle sub-assembly.

    7. for 8 Speakers:


      1. Disconnect the connector.

  11. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A00416C

      Disconnect the rear door lock remote control cable assembly and rear door inside locking cable assembly, and remove the rear door inside handle sub-assembly.

  12. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP


    1. A0041AD

      Disengage the 7 claws and remove the rear door inner glass weatherstrip from the rear door trim board sub-assembly as shown in the illustration.

  13. REMOVE REAR NO. 2 SPEAKER ASSEMBLY (for 8 Speakers)


    1. A0040BJ

      Remove the 2 screws and rear No. 2 speaker assembly.

  14. REMOVE REAR DOOR FRAME GARNISH


    1. A0042K3

      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 the rear door frame garnish.

  15. REMOVE REAR SPEAKER ASSEMBLY


    1. A0040E8

      Disconnect the connector.

    2. Using a drill bit with a diameter of less than 5 mm (0.197 in.), drill out the 3 rivet heads and remove the rear speaker assembly.

      Note


      • Do not touch the cone part of the speaker.

      • Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head.

      • Be careful as the cut rivet will be very hot.

    3. Continue drilling and push out the remaining rivet fragments.

    4. Using a vacuum cleaner, remove the rivet fragments and shavings from the inside of the door.

  16. REMOVE REAR DOOR TRIM BRACKET


    1. A0040UH

      Remove the 2 screws and rear door trim bracket.

  17. REMOVE REAR DOOR SERVICE HOLE COVER


    1. A0043E5

      Disconnect the 2 connectors.

    2. Disengage the clamp.

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

    4. Remove the rear door service hole cover.

      Tech Tips

      Remove any remaining butyl tape from the door.

  18. REMOVE REAR DOOR CHECK ASSEMBLY


    1. A00430P

      Remove the 3 bolts and rear door check assembly.

  19. REMOVE REAR DOOR WEATHERSTRIP


    1. A00411Z

      Using a clip remover, disengage the 18 clips and remove the front door weatherstrip.

  20. REMOVE REAR DOOR GLASS RUN


    1. A0043F9

      Remove the rear door glass run.

  21. REMOVE REAR DOOR WINDOW GUIDE SUB-ASSEMBLY


    1. A0043SQ

      Remove the screw.

    2. Remove the bolt and rear door window guide sub-assembly.

  22. REMOVE REAR DOOR REAR GUIDE SEAL


    1. A004411E01
      Text in Illustration
      *1 Temporary Screw

      Loosen the temporary screw.

    2. Remove the 2 screws and rear door rear guide seal.

    3. Remove the temporary screw from the rear door rear guide seal.

  23. REMOVE REAR DOOR GLASS SUB-ASSEMBLY


    1. Connect the cable to the negative (-) auxiliary battery terminal and rear power window regulator switch assembly.

    2. Connect the rear power window regulator motor connector.

    3. Move the rear door glass sub-assembly so that the door glass bolts can be seen.

    4. Disconnect the cable from the negative (-) auxiliary battery terminal.

    5. Disconnect the rear power window regulator switch assembly and rear power window regulator motor connector.

    6. A00416K

      Remove the 2 bolts and rear door glass sub-assembly as shown in the illustration.

      Note


      • After the bolts are removed, do not allow the door glass to fall.

      • Do not damage the door glass.

  24. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY


    1. A0042PRE01
      Text in Illustration
      *1 Temporary Bolt

      Loosen the temporary bolt.

      Note

      Do not remove the temporary bolt. If the temporary bolt is removed, the rear door window regulator may fall and cause damage.

    2. Remove the 5 bolts.

    3. Remove the rear door window regulator assembly.

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

  25. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY


    1. A0041RZ

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

  26. REMOVE REAR DOOR LOCK ASSEMBLY (w/o Double Locking System)


    1. A0042R3E01

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

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

      Text in Illustration
      *1 Release Plate
    3. A0040N3

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

  27. REMOVE REAR DOOR LOCK ASSEMBLY (w/ Double Locking System)


    1. A0041AKE01

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

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

      Text in Illustration
      *1 Release Plate
    3. A003ZYQ

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

  28. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)


    1. A00418U

      Using a screwdriver, disengage the 2 claws as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A00426X

      Remove the rear door lock remote control cable assembly as shown in the illustration.

  29. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)


    1. A0042DD

      Using a screwdriver, disengage the 2 claws as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A0041DL

      Remove the rear door lock remote control cable assembly as shown in the illustration.

  30. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)


    1. A0042WO

      Using a screwdriver, disengage the 4 claws as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A0043SO

      Remove the rear door inside locking cable assembly as shown in the illustration.

  31. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)


    1. A0044B5

      Using a screwdriver, disengage the 4 claws as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A0042CA

      Remove the rear door inside locking cable assembly as shown in the illustration.

  32. REMOVE REAR DOOR OUTSIDE HANDLE COVER


    1. A0040PG

      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.

  33. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A00429F

      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. A004025

      Move the lever in the direction indicated by the arrow in the illustration.

    3. A0042YG

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

  34. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A00446G

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

  35. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A0040FI

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

  36. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. A004200

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

    2. Slide the rear door outside handle frame sub-assembly to disengage the door handle nut and claw of the rear door outside handle frame sub-assembly, and then remove it.

  37. REMOVE REAR DOOR PANEL CUSHION


    1. A0044B8

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

  38. REMOVE REAR DOOR BELT MOULDING ASSEMBLY


    1. A0043RDE01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the rear door belt moulding assembly.

    2. A00440G

      Using a screwdriver, disengage the 7 claws and remove the rear door belt moulding assembly.

  39. 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 rear door front window frame moulding moulding excessively.


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

    2. A00410UE01
      Text in Illustration
      *1 Double-sided Tape

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

  40. 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 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A0040CM

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

      Tech Tips

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

  41. 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 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A00405B

      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.

  42. REMOVE REAR DOOR UPPER OUTSIDE STRIPE


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

      Heating Temperature
      Item Temperature
      Vehicle Body 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A0042OL

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

      Tech Tips

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

  43. 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 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A003ZXH

      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.