Front Door: Disassembly

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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COURTESY LIGHT ASSEMBLY
1. Disengage the claw and remove the courtesy light assembly.
2. Disconnect the connector.
  
  Fig 3: Identifying Courtesy Light Assembly Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY
1. Remove the 2 screws.
2. Using the clip remover, disengage the 9 clips.
  
  Fig 4: Identifying Front Door Trim Board Sub-Assembly Screws And Clips
  Courtesy 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 Front Door Trim Board Sub-Assembly
  Courtesy 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.
REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (See REMOVAL )
REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP
1. Disengage the 4 clips as shown in the illustration and remove the front door inner glass weatherstrip from the front door trim board.
  
  Fig 7: Identifying Front Door Inner Glass Weatherstrip Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Remove the 3 screws and the bracket.
  
  Fig 8: Identifying Bracket Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 screws and the front door inside handle sub-assembly.
REMOVE SEAT MEMORY SWITCH (w/ Seat Position Memory System) (See REMOVAL )
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: Identifying Front Door Trim Cover Screw And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR FRAME GARNISH
1. Using the clip remover, remove the 2 clips and the door frame garnish.
Fig 11: Identifying Door Frame Garnish Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See REMOVAL )
REMOVE FRONT NO. 3 SPEAKER ASSEMBLY (See REMOVAL )
REMOVE OUTER MIRROR CONTROL ECU (w/ Memory)
1. Disconnect each connector.
2. Remove the 2 screws and the outer mirror control ECU.
  
  Fig 12: Locating Outer Mirror Control ECU Screws (W/ Memory)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR SERVICE HOLE COVER
1. Disconnect each connector and each clamp, and remove the front door service hole cover.
  HINT:
  
  Remove the remaining butyl tape on the door side.
  
  Fig 13: Identifying Front Door Service Hole Cover Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Hole Plug
  Courtesy 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: Identifying Front Door Glass Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the front door glass sub-assembly as shown in the illustration.
  NOTE: Do not damage the door glass.
5. Disconnect the power window regulator master switch assembly.
  
  Fig 16: Removing Front Door Glass Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Temporary Bolt
  Courtesy 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.
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: Locating Front Power Window Regulator Motor Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Identifying Front No. 1 Door Stiffener Cushion Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR GLASS RUN
1. Remove the front door glass run.
  
  Fig 20: Identifying Front Door Glass Run
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY
1. Remove the 2 bolts and the front door front lower frame sub-assembly as shown in the illustration.
  
  Fig 21: Removing Front Door Front Lower Frame Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
1. Remove the bolt and the front door rear lower frame sub-assembly as shown in the illustration.
  
  Fig 22: Removing Front Door Rear Lower Frame Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  HINT:
  
  The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.
  
  Fig 24: Identifying Hole Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the connector.
4. Using a "torx" socket wrench (T30), loosen the screw.
  
  Fig 25: Locating Front Door Outside Handle Assembly Connector And Screw
  Courtesy 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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Disengage the 3 claws and remove the front door front outside handle pad.
  
  Fig 27: Identifying Front Door Front Outside Handle Pad Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Disengage the 2 claws and remove the front door rear outside handle pad.
  
  Fig 28: Identifying Front Door Rear Outside Handle Pad Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 Front Door Lock Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
1. Remove the front door lock remote control cable assembly.
  
  Fig 30: Identifying Front Door Lock Remote Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY
1. Using a screwdriver, disengage the 3 claws.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 31: Identifying Front Door Inside Locking Cable Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the front door inside locking cable assembly.
  
  Fig 32: Identifying Front Door Inside Locking Cable Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR ELECTRICAL KEY OSCILLATOR
1. Remove the screw and door electrical key oscillator.
REMOVE OUTER MIRROR PROTECTOR (See REMOVAL )
REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See REMOVAL )
REMOVE FRONT DOOR CHECK COVER
1. Remove the front door check cover.
  
  Fig 35: Identifying Front Door Check Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR CHECK ASSEMBLY
1. Remove the bolt, 2 nuts, and then front door check assembly.
  
  Fig 36: Identifying Front Door Check Assembly Bolt And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WEATHERSTRIP
1. Using the clip remover, disengage the 21 clips and remove the front door weatherstrip.
REMOVE FRONT DOOR FRAME COVER (See REMOVAL )
REMOVE FRONT DOOR BELT MOLDING ASSEMBLY (See REMOVAL )
REMOVE FRONT DOOR REAR WINDOW FRAME MOLDING (See REMOVAL )
REMOVE FRONT DOOR UPPER WINDOW FRAME MOLDING (See REMOVAL )