Toyota CH-R Service Manual: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during the rear door removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effects / Inoperative when not performed	Link
Disconnect cable from negative battery terminal	Initialize back door lock	Power door lock control system
	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)
		Pre-collision system
Rear door window regulator assembly Rear door glass sub-assembly Rear door glass run	Initialize Power Window Control System	Auto up and down function Jam protection function Catch protection function Remote control function Key-linked function Wireless transmitter-linked function Key-off operation function Window open warning function

PROCEDURE

1. PRECAUTION

NOTICE:

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

Click here

NOTICE:

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

Click here

3. REMOVE REAR DOOR REAR FRAME BRACKET

(a) Disengage the claws and clip to remove the rear door rear frame bracket as shown in the illustration.

Remove in this Direction

4. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG

(a) Using a moulding remover A, disengage the claws to remove the rear door inside handle bezel plug as shown in the illustration.

Remove in this Direction

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

(a) Disengage the claws, clips and guides as shown in the illustration.

Remove in this Direction

(b) Disconnect the connector to remove the rear power window regulator switch assembly with rear door armrest base upper panel.

6. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) Remove the 3 screws.

(b) Remove the 2 screws.

	Place Hands Here
	Remove in this Direction

(c) Disengage the clips and guide as shown in the illustration.

(d) Disengage the claws as shown in the illustration.

Remove in this Direction

(e) Disengage the guides to disconnect the rear door inside locking cable assembly and rear door lock remote control cable assembly to remove the rear door trim board sub-assembly as shown in the illustration.

*1	Rear Door Inside Locking Cable Assembly
*2	Rear Door Lock Remote Control Cable Assembly
	Remove in this Direction

7. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Disengage the claw and guides to remove the front door inside handle sub-assembly.

8. REMOVE REAR DOOR BELT REAR SEAL

(a) Remove the rear door belt rear seal.

9. REMOVE REAR DOOR GLASS INNER WEATHERSTRIP

(a) Remove the rear door glass inner weatherstrip with the rear door belt seal as shown in the illustration.

Remove in this Direction

10. REMOVE REAR DOOR BELT SEAL

(a) Remove the rear door belt seal from the rear door glass inner weatherstrip as shown in the illustration.

Remove in this Direction

11. REMOVE HOLE PLUG

(a) Remove the 2 hole plugs.

12. REMOVE NO. 2 REAR DOOR FRAME GARNISH

(a) Remove the No. 2 rear door frame garnish.

13. REMOVE REAR DOOR TRIM BRACKET

(a) Remove the 2 screws and rear door trim bracket.

14. REMOVE REAR DOOR INSIDE PANEL REINFORCE SUB-ASSEMBLY (w/ Rear Seat Side Airbag)

(a) Remove the 4 screws and rear door inside panel reinforce sub-assembly.

15. REMOVE REAR DOOR SERVICE HOLE COVER

(a) Remove the rear door service hole cover.

Butyl Tape

HINT:

Remove any remaining butyl tape from the rear door panel.

16. REMOVE NO. 2 SEPARATOR DOOR STIFFENER CUSHION (w/ Rear Seat Side Airbag)

(a) Remove the 2 bolts.

Double-sided Tape

(b) Peel back the double-sided tape.

(c) Disengage the guides to remove the No. 2 separator door stiffener cushion.

NOTICE:

Remove any remaining double-sided tape from the rear door panel.

17. REMOVE REAR DOOR CUSHION (w/ Rear Seat Side Airbag)

(a) Remove the 2 bolts.

(b) Disengage the hooks to remove the rear door cushion.

18. REMOVE REAR DOOR CHECK ASSEMBLY

(a) Remove the 3 bolts and rear door check assembly.

19. REMOVE REAR DOOR WEATHERSTRIP

(a) Using a clip remover, disengage the clip (A) and other clips.

*a	Clip (A)
	Double-sided Tape

(b) Remove the double-sided tape and rear door weatherstrip.

NOTICE:

Remove any remaining double-sided tape from the rear door panel.

20. REMOVE REAR DOOR WINDOW REAR LOWER FRAME SUB-ASSEMBLY

(a) Remove the screw and 2 bolts.

(b) Remove the rear door window rear lower frame sub-assembly from the rear door glass run.

21. REMOVE REAR DOOR GLASS SUB-ASSEMBLY

(a) Disengage the rear door glass sub-assembly from the rear door window regulator sub-assembly as shown in the illustration. NOTICE: After separating the rear door glass sub-assembly, do not allow it to fall.

(b) Remove the rear door glass sub-assembly as shown in the illustration.

NOTICE:

Do not damage the rear door glass sub-assembly.

	Remove in this Direction (1)
	Remove in this Direction (2)

22. REMOVE REAR DOOR FRAME GARNISH

(a) Disengage the guides to remove the rear door frame garnish.

23. REMOVE REAR DOOR GLASS RUN

(a) Remove the rear door glass run.

24. REMOVE REAR DOOR WINDOW REGULATOR ASSEMBLY

(a) Disconnect the connector.

*a Temporary Bolt

(b) Loosen the temporary bolt.

NOTICE:

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

(c) Remove the 3 bolts and rear door window regulator assembly.

(d) Remove the temporary bolt from the rear door window regulator assembly.

25. REMOVE REAR DOOR QUARTER WINDOW GLASS

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

Remove in this Direction

26. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP

(a) Remove the rear door quarter window weatherstrip from the rear door quarter window glass.

27. REMOVE REAR DOOR BELT MOULDING ASSEMBLY

Click here

28. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY

(a) Disconnect the No. 1 rear door lock remote control cable assembly from the clamps.

(b) Remove the 3 bolts.

(c) Peel back the double-sided tape.

Double-sided Tape

(d) Disengage the claws from the rear door service hole as shown in the illustration to separate the rear door outside handle assembly together with the rear door outside handle cover as a single unit.

Push

CAUTION:

Be careful not to cut your hands or fingers on the edge of the rear door panel.

HINT:

If your hands cannot fit, use a tool such as a screwdriver with its tip wrapped in protective tape to disengage the claws.

(e) Disengage the guide to disconnect the No. 1 rear door lock remote control cable assembly to remove the rear door outside handle assembly with the rear door outside handle cover. NOTICE: Remove any remaining double-sided tape from the rear door panel.

29. REMOVE REAR DOOR OUTSIDE HANDLE COVER

(a) Disengage the clips and guide to remove the rear door outside handle cover.

30. REMOVE REAR DOOR OUTSIDE HANDLE SEAL

(a) Remove the 2 rear door outside handle seals.

31. REMOVE REAR DOOR LOCK WITH MOTOR ASSEMBLY

Click here

32. REMOVE REAR DOOR DUST PROOF SEAL

(a) Remove the 3 rear door dust proof seals.

33. REMOVE REAR SPEAKER ASSEMBLY

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34. REMOVE REAR DOOR PANEL CUSHION

(a) Disengage the claws to remove the 2 rear door panel cushions.

35. REMOVE REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY

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36. REMOVE REAR DOOR OUTSIDE MOULDING

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37. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING

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38. REMOVE REAR DOOR REAR WINDOW FRAME MOULDING

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39. REMOVE REAR DOOR LOWER OUTSIDE STRIPE

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40. REMOVE REAR DOOR OUTSIDE STRIPE

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