This manual outlines the disassembly procedures for various components of a rear door, likely for a vehicle such as the Lexus IS200. It provides step-by-step instructions for removing parts like the inside handle bezel, power window switch, rear armrest, door trim, inside handle, service hole cover, service hole plate, door glass run, rear door belt moulding, division bar, rear door quarter window glass, door glass, window regulator, door lock, outside handle, and cushions. The instructions are accompanied by illustrations to guide the user through each step.
REMOVE INSIDE HANDLE BEZEL
The inside handle bezel is a decorative and functional trim piece surrounding the interior door handle. Its removal is the first step in accessing underlying components.
- Function Description: Covers the mounting screws for the inside handle and provides a finished look to the door panel.
- Usage Features: To remove, first open the screw cap using a screwdriver. It's recommended to tape the screwdriver tip before use to prevent scratching the bezel or surrounding surfaces. After removing the screw, the bezel can be carefully pried off using a screwdriver, following the illustration for proper leverage points.
- Maintenance Features: Taping the screwdriver tip is a key maintenance tip to prevent cosmetic damage during removal.
REMOVE POWER WINDOW SWITCH
The power window switch controls the operation of the power window. Its removal is necessary for deeper access into the door panel or for replacement of the switch itself.
- Function Description: Allows the user to raise and lower the rear door window electronically.
- Usage Features: The switch is typically secured by clips or screws. A screwdriver is used to carefully remove the switch from its housing. As with the bezel, taping the screwdriver tip is advised to prevent damage. Once the switch is loose, its electrical connector must be disconnected.
- Maintenance Features: Taping the screwdriver tip protects the switch and surrounding trim from scratches. Disconnecting the connector properly ensures no electrical damage.
REMOVE REAR ARMREST
The rear armrest provides a comfortable resting place for occupants' arms and often integrates storage or other controls.
- Function Description: Provides ergonomic support for rear passengers and may house additional components or fasteners.
- Usage Features: Removal typically involves unscrewing a visible fastener. After the screw is removed, a screwdriver can be used to carefully pry the armrest away from the door panel. The illustration should be consulted for the correct prying points. Taping the screwdriver tip is recommended.
- Maintenance Features: Taping the screwdriver tip prevents damage to the armrest or door panel during removal.
REMOVE DOOR TRIM
The door trim is the interior panel that covers the door's internal mechanisms, providing a finished appearance and sound insulation.
- Function Description: Covers the internal structure of the door, provides aesthetic appeal, and often incorporates the armrest, window switch, and other controls.
- Usage Features: The door trim is primarily held in place by clips. A screwdriver is used to disengage these clips. Once the clips are released, the trim is pulled upward to remove it from the door frame. Taping the screwdriver tip is crucial to avoid scratching the trim.
- Maintenance Features: Taping the screwdriver tip is essential to prevent cosmetic damage to the large, visible door trim panel.
REMOVE INSIDE HANDLE
The inside handle is used to open the door from the interior.
- Function Description: Mechanically actuates the door latch to open the door from the inside.
- Usage Features: After removing the inside handle bezel, a screw securing the handle is removed. The handle itself is then detached, and two cables connected to it must be disconnected. These cables are part of the door's locking and latching mechanism.
- Maintenance Features: Careful handling of the cables is important to avoid damage to the door's opening mechanism.
REMOVE SERVICE HOLE COVER
The service hole cover is a protective barrier, often made of plastic sheeting or foam, that seals the door's interior.
- Function Description: Prevents water, dust, and noise from entering the vehicle's cabin through the door's internal cavity. It also helps with sound dampening.
- Usage Features: First, any electrical connectors passing through or attached to the cover must be disconnected. If the vehicle has a "Double locking" system, two screws and a door trim bracket need to be removed. Finally, the service hole cover itself can be carefully peeled away.
- Maintenance Features: Ensuring all connectors are properly disconnected prevents electrical damage. Careful removal of the cover helps preserve its integrity for reinstallation.
REMOVE SERVICE HOLE PLATE
The service hole plate is a more rigid panel, typically metal, that provides structural support and access to certain door components.
- Function Description: Provides structural integrity to the door and allows access to internal components for service and repair.
- Usage Features: Two screws securing the service hole plate must be removed. Once the screws are out, the plate can be detached.
- Maintenance Features: Proper reinstallation of the screws ensures the plate's structural contribution is maintained.
REMOVE DOOR GLASS RUN
The door glass run is a rubber or felt channel that guides the door glass as it moves up and down.
- Function Description: Provides a smooth, sealed track for the door glass, reducing friction and preventing water and wind intrusion.
- Usage Features: The manual indicates that this step is simply "REMOVE DOOR GLASS RUN," implying it can be pulled out of its channel after other components are removed.
- Maintenance Features: Inspecting the glass run for wear or damage during removal can help identify potential issues with window operation or sealing.
REMOVE REAR DOOR BELT MOULDING
The rear door belt moulding is an exterior trim piece located along the bottom edge of the window opening.
- Function Description: Provides a decorative finish to the exterior of the door and helps seal the gap between the door panel and the window glass.
- Usage Features: A screw must first be removed. To prevent scratching the outer surface of the door during removal, protective tape should be applied as shown in the illustration. A moulding remover tool is then used to carefully pry off the belt moulding.
- Maintenance Features: Applying protective tape is a critical maintenance step to prevent cosmetic damage to the vehicle's exterior paint. Using a dedicated moulding remover tool minimizes the risk of damage to the moulding itself.
REMOVE DIVISION BAR
The division bar is a vertical support or guide within the door frame, often separating the main window from a quarter window.
- Function Description: Provides structural support within the door frame and guides the movement of the window glass.
- Usage Features: This involves removing two bolts and a screw. Once these fasteners are removed, the division bar is pulled forward. To fully remove it, the bar must be rotated 90 degrees and then pulled upward, as illustrated.
- Maintenance Features: Careful handling during rotation and upward pulling prevents bending or damaging the bar.
REMOVE REAR DOOR QUARTER WINDOW GLASS
The rear door quarter window glass is a small, fixed window often found in the rear doors of certain vehicles.
- Function Description: Provides additional visibility and contributes to the vehicle's aesthetic design.
- Usage Features: The illustration guides the removal process. A crucial notice is provided: "Do not damage the glass." After the glass is removed, the quarter window weatherstrip must also be removed from the glass.
- Maintenance Features: Extreme care is required to prevent damage to the glass, which can be costly to replace. Proper removal of the weatherstrip ensures its integrity for reinstallation.
REMOVE DOOR GLASS
The door glass is the main window pane in the door.
- Function Description: Allows for visibility and ventilation, and is operated by the window regulator.
- Usage Features: Before removal, a shop rag should be inserted inside the door panel to prevent scratching the glass. The door glass is then opened. To remove it, the glass must be tilted, and the roller of the window regulator disconnected from the glass channel.
- Maintenance Features: Using a shop rag is a simple yet effective maintenance tip to protect the glass from scratches during removal. Careful disconnection of the regulator roller prevents damage to the window mechanism.
REMOVE WINDOW REGULATOR
The window regulator is the mechanism that moves the door glass up and down.
- Function Description: Mechanically controls the vertical movement of the door glass, typically powered by an electric motor.
- Usage Features: First, the electrical connector to the regulator motor must be disconnected. Then, four bolts securing the window regulator are removed.
- Maintenance Features: Disconnecting the connector properly prevents electrical shorts or damage. Ensuring all bolts are removed prevents damage to the regulator or door frame during extraction.
REMOVE DOOR LOCK
The door lock mechanism controls the locking and unlocking of the door.
- Function Description: Secures the door in a closed position and allows for locking and unlocking from both inside and outside the vehicle.
- Usage Features: The child protection cover must be removed first. Then, two links connected to the outside handle and key cylinder need to be disconnected. A bolt and a screw are removed. For certain models, a torx socket wrench (T30, Part No. 09042-00010 or a locally manufactured tool) is required to remove three torx screws and the door lock itself. The door lock is then removed through the service hole. Finally, its electrical connector is disconnected.
- Maintenance Features: Using the correct torx socket wrench is crucial to avoid stripping the screw heads. Careful disconnection of the links and electrical connector prevents damage to the locking system.
REMOVE OUTSIDE HANDLE
The outside handle is used to open the door from the exterior.
- Function Description: Mechanically actuates the door latch to open the door from the outside.
- Usage Features: Two bolts securing the outside handle are removed, and then the handle can be detached.
- Maintenance Features: Proper removal of the bolts ensures no damage to the handle or its mounting points.
REMOVE CUSHIONS
Cushions, in this context, likely refer to sound-dampening or protective padding within the door.
- Function Description: Provides sound insulation, reduces vibrations, and protects internal components from impact.
- Usage Features: The manual simply states "REMOVE CUSHIONS," implying they can be pulled or peeled away once other components are removed.
- Maintenance Features: Careful removal helps preserve the cushions for reinstallation, maintaining their sound-dampening and protective properties.
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