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Front Door: Disassembly

  1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a screwdriver wrapped with protective tape, disengage the 3 claws, and remove the front door inside handle bezel plug.
    Fig 1: Removing Front Door Inside Handle Bezel Plug
    G04051320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY 
    1. Using a screwdriver wrapped with protective tape, disengage the 4 claws and the 2 clips.
    2. Disconnect the connector and remove the power window regulator master switch assembly.
    Fig 2: Removing Power Window Regulator Master Switch Assembly
    G04051321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE COURTESY LIGHT ASSEMBLY 
    1. Disengage the claw and remove the courtesy light assembly.
    2. Disconnect the connector.
    Fig 3: Removing Courtesy Light Assembly
    G04051322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 2 screws.
    2. Using the clip remover, disengage the 9 clips.
      Fig 4: Removing Front Door Trim Board Sub-Assembly Clips
      G04051323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull out the front door trim board in the direction indicated by the arrow.
    4. Remove the reference bosses from the front door panel.
    5. Raise the front door trim board to disengage the 4 claws and remove the front door trim board together with the front door inner glass weatherstrip.
      Fig 5: Removing Reference Bosses From Front Door Panel
      G04051324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the cables and each connector from the back side of the inside handle and remove the front door trim board sub-assembly.
    7. Remove the 2 front door trim board retainers (green) from the front door trim board.
    Fig 6: Disconnecting Cables & Each Connector From Back Side Of Inside Handle
    G04051325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (See Step 6 in  REMOVAL  ) 
  6. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Disengage the 4 clips and remove the front door inner glass weatherstrip from the front door trim board.
    Fig 7: Removing Front Door Inner Glass Weatherstrip From Front Door Trim Board
    G04051326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Remove the 3 screws and the bracket.
      Fig 8: Removing Screws & Bracket
      G04051327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 screws and the front door inside handle sub-assembly.
    Fig 9: Removing Screws & Front Door Inside Handle Sub-Assembly
    G04051328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE SEAT MEMORY SWITCH (w/ Seat Position Memory System) (See Step 6 in  REMOVAL  ) 
  9. REMOVE FRONT DOOR TRIM COVER 
    1. Remove the screw.
    2. Using the clip remover, disengage the 6 clips and remove the front door trim cover.
    Fig 10: Removing Front Door Trim Cover
    G04051329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE DOOR FRAME GARNISH 
    1. Using the clip remover, remove the 2 clips and the door frame garnish.
    Fig 11: Removing Clips & Door Frame Garnish
    G04051330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See Step 5 in  REMOVAL  ) 
  12. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (See Step 7 in  REMOVAL  ) 
  13. REMOVE OUTER MIRROR CONTROL ECU (w/ Memory) 
    1. Disconnect each connector.
    2. Remove the 2 screws and the outer mirror control ECU.
    Fig 12: Removing Screws & Outer Mirror Control ECU
    G04051331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Disconnect each connector and each clamp, and remove the front door service hole cover.
    Fig 13: Disconnecting Connector & Clamp
    G04051332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    Remove the remaining butyl tape on the door side.

  15. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the hole plug.
    2. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
      Fig 14: Connecting Power Window Regulator Master Switch Assembly
      G04051333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts.
      NOTE: After the bolts are removed, the door glass may fall and become deformed.
      Fig 15: Removing Door Glass May Fall
      G04051334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front door glass sub-assembly.
      Fig 16: Removing Front Door Glass Sub-Assembly
      G04051335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not damage the door glass.
    5. Disconnect the power window regulator master switch assembly.
  16. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Disconnect the connector.
    2. Loosen the temporary bolt.
      NOTE: If the temporary bolt is removed, the front door window regulator may fall and become deformed.
    3. Remove the 5 bolts.
      Fig 17: Removing Bolts
      G04051336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front door window regulator sub-assembly and the power window regulator motor assembly front as a unit.
    5. Remove the temporary bolt from the front door window regulator sub-assembly.
  17. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    1. Using a "torx" driver (T25), remove the 3 screws and the front power window regulator motor assembly.
    Fig 18: Removing Screws & Front Power Window Regulator Motor Assembly
    G04051337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT NO. 1 DOOR STIFFENER CUSHION 
    1. Remove the 2 bolts.
    2. Remove the double-sided tape and the front No. 1 door stiffener cushion.
    Fig 19: Removing Double-Sided Tape & Front No. 1 Door Stiffener Cushion
    G04051338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
    Fig 20: Removing Front Door Glass Run
    G04051339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts and the front door front lower frame sub-assembly.
      Fig 21: Removing Front Door Front Lower Frame Sub-Assembly
      G04051340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the bolt and the front door rear lower frame sub-assembly.
    Fig 22: Removing Bolt & Front Door Rear Lower Frame Sub-Assembly
    G04051341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER 
    1. Using an emergency key, disengage the 2 claws and remove the front door outside handle cover.
    Fig 23: Removing Front Door Outside Handle Cover
    G04051342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Remove the hole plug.
    2. Using a "torx" socket wrench (T30), loosen the screw and remove the front door outside handle cover and the door lock key cylinder as a unit.
      Fig 24: Removing Front Door Outside Handle Cover & Door Lock Key Cylinder
      G04051343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

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

    3. Disconnect the connector.
    4. Using a "torx" socket wrench (T30), loosen the screw.
      Fig 25: Door Outside Handle Sub-Assembly, Connector & Screw
      G04051374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the front door outside handle assembly as shown in the illustration.
    Fig 26: Removing Front Door Outside Handle Assembly
    G04051345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws and remove the front door front outside handle pad.
    Fig 27: Removing Front Door Front Outside Handle Pad
    G04051346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws and remove the front door rear outside handle pad.
    Fig 28: Removing Front Door Rear Outside Handle Pad
    G04051347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FRONT DOOR LOCK ASSEMBLY 
    1. Using a "torx" socket wrench (T30), remove the 3 screws.
    2. Slide the front door lock assembly downward, pull out the front door lock open rod from the outside handle frame, and remove the front door lock assembly and cables as a unit.
    3. Remove the front door lock open rod from the front door lock assembly.
    4. Remove the door lock wiring harness sealing from the front door lock assembly.
    Fig 29: Identifying Door Lock Assembly With Screws
    G04049949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Remove the front door lock remote control cable assembly.
    Fig 30: Removing Front Door Lock Remote Control Cable Assembly
    G04051349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 3 claws.
      Fig 31: Disengaging Claws Using Screwdriver
      G04049939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Tape the screwdriver tip before use.

    2. Remove the front door inside locking cable assembly.
    Fig 32: Removing Front Door Inside Locking Cable Assembly
    G04051351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a "torx" socket wrench (T30), loosen the screw.

      HINT:

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

    2. Disconnect the connector.
    3. Disengage the 2 clamps.
    4. Disengage the claws and remove the front door outside handle frame sub-assembly.
    Fig 33: Removing Front Door Outside Handle Frame Sub-Assembly
    G04051352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE DOOR ELECTRICAL KEY OSCILLATOR 
    1. Remove the screw and door electrical key oscillator.
    Fig 34: Removing Screw & Door Electrical Key Oscillator
    G04051353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE OUTER MIRROR PROTECTOR (See Step 9 in  REMOVAL  ) 
  32. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See Step 10 in  REMOVAL  ) 
  33. REMOVE FRONT DOOR CHECK COVER 
    1. Remove the front door check cover.
    Fig 35: Removing Front Door Check Cover
    G04051354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts, and then front door check assembly.
    Fig 36: Removing Front Door Check Assembly
    G04051355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using the clip remover, disengage the 21 clips and remove the front door weatherstrip.
    Fig 37: Removing Front Door Weatherstrip
    G04051356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR FRAME COVER (See Step 6 in  REMOVAL  ) 
  37. REMOVE FRONT DOOR BELT MOLDING ASSEMBLY (See Step 7 in  REMOVAL  ) 
  38. REMOVE FRONT DOOR REAR WINDOW FRAME MOLDING (See Step 11 in  REMOVAL  ) 
  39. REMOVE FRONT DOOR UPPER WINDOW FRAME MOLDING (See Step 12 in  REMOVAL  ) 
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