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Disassembly [08/2013 - ]

WARNING: This page is about a different car, the 2014 Lexus ES 300h. However, it is still accessible from the selected car via links, so may be relevant.

HINT: 

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work. Refer to PRECAUTION [08/2013 - ] .

  2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER  . Refer to REMOVAL [08/2013 - ] - Step 2
  3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL 
    WARNING:

    Wait at least 90 seconds after disconnecting the cable from the auxiliary battery negative (-) terminal to disable the SRS system.

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION [08/2013 - ] .

  4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a molding remover, disengage the 3 claws and remove the front door inside handle bezel plug as shown in the illustration.
      Fig 1: Removing Front Door Inside Handle Bezel Plug
      GTY417860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) 
    1. Using a molding remover, disengage the 2 clips, 6 claws and 2 guides as shown in the illustration.
      Fig 2: Removing Multiplex Network Master Switch Assembly With Front Door Armrest Base Panel (For Driver Side)
      GTY404463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect each connector and remove the multiplex network master switch assembly with front door armrest base panel.
  6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) 
    1. Using a molding remover, disengage the 2 clips, 6 claws and 2 guides as shown in the illustration.
      Fig 3: Removing Power Window Regulator Switch Assembly With Front Door Armrest Base Panel (For Front Passenger Side)
      GTY404465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect each connector and remove the power window regulator switch assembly with front door armrest base panel.
  7. REMOVE DOOR PULL HANDLE COVER 
    1. Remove the door pull handle cover.
      Fig 4: Identifying Door Pull Handle Cover
      GTY396398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE COURTESY LIGHT ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 1
  9. REMOVE FRONT DOOR NO. 1 STIFFENER CUSHION 
    1. Remove the screw and front door No. 1 stiffener cushion.
      Fig 5: Identifying Front Door No. 1 Stiffener Cushion Screw
      GTY398753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Put protective tape around the front door panel.
      Fig 6: Identifying Protective Tape Around Front Door Panel
      GTY416217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Protective Tape
    2. Remove the 3 screws.
      Fig 7: Identifying Front Door Trim Board Sub-Assembly Screws
      GTY414614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a clip remover, disengage the 11 clips.
      Fig 8: Identifying Front Door Trim Board Sub-Assembly Clips
      GTY414460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Pull out the front door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.
      Fig 9: Identifying Front Door Trim Board Sub-Assembly
      GTY396644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Reference Boss
      *2 Front Door Inner Glass Weatherstrip
    5. Disengage the reference boss from the front door panel.
    6. Raise the front door trim board sub-assembly and disconnect the front door trim board sub-assembly together with the front door inner glass weatherstrip.
    7. w/ Memory:
      1. Disconnect the connector.
    8. w/ Illumination:
      1. Disconnect the connector.
    9. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly to remove the front door trim board sub-assembly together with the front door inner glass weatherstrip.
      Fig 10: Front Door Lock Remote Control And Front Door Inside Locking Cable Assemblies
      GTY404459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Using a screwdriver, disengage the 4 claws and remove the front door inner glass weatherstrip from the front door trim board sub-assembly as shown in the illustration.
      Fig 11: Removing Front Door Inner Glass Weatherstrip
      GTY412564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Screwdriver
  12. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the claw and 2 guides, and remove the front door inside handle sub-assembly.
      Fig 12: Identifying Front Door Inside Handle Sub-Assembly Guides
      GTY417250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE SEAT MEMORY SWITCH (w/ Memory)  . Refer to REMOVAL [08/2013 - ] - Step 2
  14. REMOVE FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel and Bamboo Panel) 
    1. w/ Illumination:
      1. Disengage the 3 clamps.
        Fig 13: Identifying Front Door Trim Ornament Sub-Assembly Clamps
        GTY401200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 11 screws and front door trim ornament assembly.
      Fig 14: Identifying Front Door Trim Ornament Assembly Screws
      GTY401285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the screw.
      Fig 15: Identifying Front Door Trim Ornament Assembly Screws
      GTY400185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the claw and remove the front door trim ornament sub-assembly.
  15. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)  . Refer to REMOVAL [08/2013 - ] - Step 12
  16. REMOVE OUTER MIRROR PROTECTOR  . Refer to REMOVAL [08/2013 - ] - Step 13
  17. REMOVE OUTER MIRROR INSTALL HOLE COVER  . Refer to REMOVAL [08/2013 - ] - Step 14
  18. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 15
  19. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Disengage the 2 clips and remove the front door lower frame bracket garnish.
      Fig 16: Identifying Front Door Lower Frame Bracket Garnish Clips
      GTY400347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE DOOR SIDE AIRBAG SENSOR (w/ Occupant Classification System)  . Refer to REMOVAL [08/2013 - ] - Step 11
  21. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 9
  22. REMOVE FRONT DOOR ARMREST SET BRACKET 
    1. Remove the 2 screws and front door armrest set bracket.
      Fig 17: Identifying Front Door Armrest Set Bracket Screws
      GTY417020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Disconnect the 2 connectors.
      Fig 18: Identifying Occupant Classification System Connectors And Clamps
      GTY405687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *A w/ Occupant Classification System
      *B for LH Side
    2. w/ Occupant Classification System:
      1. Remove the bolt.
    3. Disengage each clamp.
    4. Remove the front door service hole cover.
      Fig 19: Identifying Front Door Service Hole Cover
      GTY404527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Remove any remaining butyl tape from the door.

  24. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the grommet.
      Fig 20: Identifying Front Door Glass Sub-Assembly Grommet
      GTY411307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the cable to the auxiliary battery negative (-) terminal.
    3. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
    4. Disconnect the cable from the auxiliary battery negative (-) terminal.
    5. Disconnect the multiplex network master switch assembly.
    6. Remove the 2 bolts.
      Fig 21: Identifying Front Door Glass Sub-Assembly Bolts
      GTY413302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After the bolts are removed, do not allow the front door glass sub-assembly to fall.

    7. Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.
      Fig 22: Identifying Front Door Glass Sub-Assembly
      GTY409781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the front door glass sub-assembly.

  25. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Loosen the temporary bolt.
      Fig 23: Identifying Front Door Window Regulator Assembly Bolts
      GTY416922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Temporary Bolt
      NOTE:

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

    2. Remove the 5 bolts.
    3. Remove the front door window regulator assembly.
    4. Remove the temporary bolt from the front door window regulator assembly.
  26. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    1. Using a T25 "TORX" socket wrench, remove the 3 screws and front power window regulator motor assembly.
      Fig 24: Identifying Front Power Window Regulator Motor Assembly Screws
      GTY412512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
      Fig 25: Identifying Front Door Glass Run
      GTY411797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      Fig 26: Identifying Front Door Front Lower Frame Sub-Assembly Bolts
      GTY412114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and remove the front door front lower frame sub-assembly.
  29. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the bolt.
      Fig 27: Identifying Front Door Rear Lower Frame Sub-Assembly Bolt
      GTY411664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and remove the front door rear lower frame sub-assembly.
  30. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
      Fig 28: Identifying Front Door Outside Handle Cover With Lock Cylinder Assembly (For Driver Side) Hole Plug
      GTY411973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover with lock cylinder assembly.
      Fig 29: Removing/Installing Front Door Outside Handle Cover With Lock Cylinder Assembly (For Driver Side) Screw
      GTY408110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

  31. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) 
    1. Using a screwdriver, disengage the claw and 2 guides, and remove the front door outside handle cover as shown in the illustration.
      Fig 30: Identifying Front Door Outside Handle Cover Claw & Guides
      GTY384255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Remove the hole plug.
      Fig 31: Identifying Remove Front Door Outside Handle Cover (For Front Passenger Side) Hole Plug
      GTY406312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.
      Fig 32: Removing/Installing Front Door Outside Handle Cover (For Front Passenger Side) Screw
      GTY418555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

  33. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Disengage the 2 claws.
      Fig 33: Removing Front Door Outside Handle Assembly
      GTY404539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disconnect the connector.
    3. Move the lever in the direction indicated by the arrow in the illustration.
      Fig 34: Identifying Front Door Outside Handle Assembly Lever
      GTY404538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front door outside handle assembly as shown in the illustration.
      Fig 35: Identifying Front Door Outside Handle Assembly
      GTY404536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws and remove the front door front outside handle pad.
      Fig 36: Identifying Front Door Front Outside Handle Pad Claws
      GTY402822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws and remove the front door rear outside handle pad.
      Fig 37: Identifying Front Door Rear Outside Handle Pad Claws
      GTY403280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR LOCK ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the 3 screws.
      Fig 38: Identifying Front Door Lock Assembly Screws And Open Rod
      GTY416976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front Door Lock Open Rod
    2. Slide the front door lock assembly downward, and remove the front door lock assembly and cables as a unit.
    3. When reusing the front door lock assembly:
      1. Remove the door lock wiring harness seal from the front door lock assembly.
        Fig 39: Identifying Front Door Lock Wiring Harness Seal
        GTY417657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Remove the front door lock remote control cable assembly as shown in the illustration.
      Fig 40: Removing Front Door Lock Remote Control Cable Assembly
      GTY404532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 3 claws as shown in the illustration.
      Fig 41: Identifying Front Door Inside Locking Cable Assembly Claws
      GTY404533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door inside locking cable assembly as shown in the illustration.
      Fig 42: Identifying Front Door Inside Locking Cable Assembly
      GTY404530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Disengage the 3 clamps.
      Fig 43: Identifying Front Door Outside Handle Frame Sub-Assembly Clamps
      GTY415127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw.
      Fig 44: Identifying Front Door Outside Handle Frame Sub-Assembly Screw
      GTY397560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Outside
      *b Inside
    3. Slide the front door outside handle frame sub-assembly to disengage the claw of the front door outside handle frame sub-assembly, and then remove it.
  40. REMOVE FRONT DOOR LOCK OPEN ROD 
    1. Remove the front door lock open rod as indicated by the arrows and in the order shown in the illustration.
      Fig 45: Removing Front Door Lock Open Rod
      GTY418535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE FRONT DOOR NO. 2 STIFFENER CUSHION 
    1. Remove the 2 bolts.
      Fig 46: Identifying Front Door No. 2 Stiffener Cushion Bolts
      GTY412832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Double-sided Tape
    2. Disengage the 2 guides and remove the front door No. 2 stiffener cushion.
  42. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the bolt and 2 nuts, and front door check assembly.
      Fig 47: Identifying Front Door Check Assembly Nuts And Bolt
      GTY399149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Nut
  43. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 21 clips and guide, and remove the front door weatherstrip.
      Fig 48: Identifying Front Door Weatherstrip Clips And Guide
      GTY417991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Double-sided Tape
  44. REMOVE DOOR FRAME GARNISH 
    1. Disengage the 3 claws and remove the door frame garnish.
      Fig 49: Identifying Door Frame Garnish Claws
      GTY398266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Using a clip remover, disengage the 9 clips and remove the front door No. 2 weatherstrip.
      Fig 50: Identifying Front Door No. 2 Weatherstrip Clips
      GTY411341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE FRONT DOOR PANEL CUSHION 
    1. Disengage the claw and remove the front door panel cushion.
      Fig 51: Identifying Front Door Panel Cushion
      GTY419140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE FRONT DOOR LOWER FRAME GARNISH PAD 
    1. Remove the front door lower frame garnish pad.
      Fig 52: Identifying Front Door Lower Frame Garnish Pad
      GTY410335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FRONT DOOR FRONT LOWER FRAME UPPER COVER  . Refer to REMOVAL [08/2013 - ] - Step 10
  49. REMOVE FRONT DOOR BELT MOLDING ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 16
  50. REMOVE FRONT DOOR REAR WINDOW FRAME MOLDING  . Refer to REMOVAL [08/2013 - ] - Step 8
  51. REMOVE FRONT DOOR OUTSIDE MOLDING SUB-ASSEMBLY  . Refer to REMOVAL [08/2013 - ] - Step 9
  52. REMOVE FRONT DOOR REAR INNER BLACK OUT TAPE  . Refer to REMOVAL [08/2013 - ] - Step 19
  53. REMOVE FRONT INNER BLACK OUT TAPE  . Refer to REMOVAL [08/2013 - ] - Step 20
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