Rear Door: Disassembly

HINT:

A bolt without a torque specification is shown in the standard bolt chart. (See SPECIFIED TORQUE FOR STANDARD BOLTS )

1. w/o Power window: REMOVE REGULATOR HANDLE 

   Pull off the snap ring with a shop rag and remove the regulator handle and plate.

   Fig 1: Removing Regulator Handle Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE DOOR INSIDE HANDLE BEZEL 
   1. Remove the screw.
   2. Using a screwdriver, pry out the bezel.

   HINT:

   Tape the screwdriver tip before use.

   Fig 2: Removing Door Inside Handle Bezel & Screw

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE DOOR TRIM BOARD 
   1. Using a screwdriver, remove the door assist grip door panel.

      HINT:

      Tape the screwdriver tip before use.

   2. Remove the 2 screws and clip.
   3. Insert a screwdriver between the door panel and door trim board to pry the door trim board loose.

      HINT:

      Tape the screwdriver tip before use.

   4. Remove the door trim board.
      Fig 3: Removing Door Trim Board, Screws & Clip

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. w/Power window: REMOVE POWER WINDOW SWITCH 
   1. Disconnect the connector.
   2. Using a screwdriver, remove the switch.

   HINT:

   Tape the screwdriver tip before use.

5. REMOVE DOOR INSIDE HANDLE 
   1. Remove the screw.
   2. Disconnect the 2 cables and remove the door inside handle.
6. REMOVE SERVICE HOLE COVER 
7. REMOVE REAR DOOR WEATHERSTRIP 

   Using a screwdriver, remove rear door weatherstrip.

   HINT:

   Tape the screwdriver tip before use.

8. REMOVE DOOR BELT MOULDING 
   1. Remove the screw.
   2. Using a moulding remover, remove the front door belt moulding.
      Fig 4: Removing Door Belt Moulding & Screw

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE DOOR SPEAKER 
   1. Disconnect the connector.
   2. Using a drill of less than diameter 4 mm (0.16 in.), drill out the rivet heads and remove the door speaker.
   3. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
      Fig 5: Removing Door Speaker & Rivets

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      • Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
      • Take cafe as the cut rivet is hot.
   4. Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
   5. Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door panel.
10. REMOVE DOOR GLASS RUN 
11. REMOVE DIVISION BAR 

    Remove the bolt, screw and division bar.

12. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP AND GLASS 
13. REMOVE DOOR GLASS AND WINDOW REGULATOR ASSEMBLY 
    NOTE:

    • Be careful not to drop the door glass and window regulator assembly.
    • Do not damage the door glass.
    1. w/Power window:

       Disconnect the connector.

    2. w/Power window:

       Remove the 3 bolts from the window regulator.

    3. w/o Power window:

       Remove the 2 bolts from the window regulator.

    4. Remove the door glass through the window regulator.
    5. Remove the window regulator through the service hole.
    6. w/Power window:

       Using a Torx wrench, remove the 3 screws and motor.

       Fig 6: Removing Door Glass & Window Regulator Assembly & Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE DOOR LOCK 
    1. w/Power door lock:

       Disconnect the connector.

    2. Disconnect the 2 links from the outside handle.
    3. Remove the 4 screws, bolt and door lock.
    Fig 7: Removing Door Lock & Screws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE DOOR OUTSIDE HANDLE 

    Remove the 2 screws and door outside handle.