LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2008 >> IS 250 RWD, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 7 ((Door / Hatch)) >> Front Door >> Disassembly

Front Door: Disassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  2. 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.
      Fig 1: Removing Front Door Inside Handle Bezel Plug
      G05755981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL 
    1. Using a molding remover, disengage the 4 claws and the 2 clips
    2. Disconnect the connector and remove the power window regulator master switch assembly with front door armrest base panel
      Fig 2: Removing Power Window Regulator Master Switch Assembly With Front Door Armrest Base Panel
      G05755982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE COURTESY LIGHT ASSEMBLY 
    1. Using a molding remover, disengage the claw and remove the courtesy light assembly
    2. Disconnect the connector
      Fig 3: Identifying Courtesy Light Assembly
      G05755983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 2 screws.
    2. Using a clip remover, disengage the 9 clips.
      Fig 4: Identifying Front Door Trim Board Sub-Assembly Clips
      G05321184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull out the front door trim board in the direction indicated by the arrow.
    4. Remove the reference boss 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: Pulling Front Door Trim Board
      G05755985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.
    7. Disconnect each connector and remove the front door trim board sub-assembly.
    8. Remove the 2 front door trim board retainers (green) from the front door trim board
    Fig 6: Locating Front Door Lock Remote Control Cable Assembly
    G05321186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY  (See REMOVAL )
  7. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Using a molding remover, 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 And Clips
      G05755987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Remove the 3 screws and the bracket
      Fig 8: Identifying Screws And Bracket
      G05321188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 screws and the front door inside handle sub-assembly.
      Fig 9: Identifying Front Door Inside Handle Sub-Assembly And Screws
      G05321189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE SEAT MEMORY SWITCH  (See REMOVAL )
  10. REMOVE FRONT DOOR TRIM COVER 
    1. Remove the screw.
    2. Using a clip remover, disengage the 6 clips and remove the front door trim cover.
      Fig 10: Identifying Front Door Trim Cover Screws
      G05321190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE DOOR FRAME GARNISH 
    1. Using a clip remover, remove the 2 clips and the door frame garnish.
    Fig 11: Identifying Door Frame Garnish And Clips
    G05321191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY  (See REMOVAL )
  13. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY  (See REMOVAL )
  14. REMOVE OUTER MIRROR CONTROL ECU  (See REMOVAL )
  15. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Disconnect each connector.
    2. Disengage each clamp and remove the front door service hole cover.

      HINT:

      Remove any remaining butyl tape from the door

      Fig 12: Locating Front Door Service Hole Cover
      G05755992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the hole plug
    2. Connect the cable to the negative (-) battery terminal and front power window motors connector.
    3. 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
    4. Disconnect the power window regulator master switch assembly and front power window motors connector
      Fig 13: Identifying Front Door Glass Sub-Assembly
      G05321194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the cable from the negative (-) battery terminal
    6. Remove the 2 bolts.
      NOTE: After the bolts are removed, do not allow the door glass to fall.
      Fig 14: Identifying Front Door Glass Sub-Assembly With Bolt
      G05321195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the front door glass sub-assembly as shown in the illustration
      NOTE: Do not damage the door glass.
      Fig 15: Removing Front Door Glass Sub-Assembly
      G05755995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Loosen the temporary bolt.
      NOTE: Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall and cause damage.
      Fig 16: Loosening Temporary Bolt
      G05755996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts
    3. Remove the front door window regulator sub-assembly and the front power window regulator motor assembly as a unit
    4. Remove the temporary bolt from the front door window regulator sub-assembly
  18. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    1. Using a "TORX" socket wrench (T25), remove the 3 screws and the front power window regulator motor assembly.
      Fig 17: Locating Front Power Window Regulator Motor Assembly And Screws
      G05321198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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 18: Identifying Front No. 1 Door Stiffener Cushion And Bolts
      G05321199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run
      Fig 19: Identifying Front Door Glass Run
      G05321200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. 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 20: Removing Front Door Front Lower Frame Sub-Assembly And Bolts
      G05321201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 21: Removing Front Door Rear Lower Frame Sub-Assembly And Bolts
      G05321202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) 
    1. Using an emergency key, disengage the 2 claws and remove the front door outside handle cover.
      Fig 22: Removing Front Door Outside Handle Cover
      G05254230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug
    2. Using a "TORX" socket wrench (T30), loosen the screw and remove the front door lock cylinder

      HINT

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

      Fig 23: Identifying Front Door Lock Cylinder Assembly (For Driver Side)
      G05252819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Remove the hole plug.
    2. Using a "TORX" socket wrench (T30), loosen the screw and remove the front door outside handle cover

      HINT

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

      Fig 24: Identifying Front Door Outside Handle Cover (For Front Passenger Side)
      G05756004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Disconnect the connector.
    2. Using a "TORX" socket wrench (T30), loosen the screw
      Fig 25: Locating Front Door Outside Handle Assembly And Screws
      G05756005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the front door outside handle assembly as shown in the illustration.
      Fig 26: Removing Front Door Outside Handle Assembly
      G05252821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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 And Claws
      G05254235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 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 And Claws
      G05321208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. 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 seal from the front door lock assembly.
      Fig 29: Removing Door Lock Wiring Harness Seal
      G05320720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. 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
      G05321210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 3 claws.

      HINT

      Tape the screwdriver tip before use

      Fig 31: Removing Front Door Inside Locking Cable Assembly
      G05320722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door inside locking cable assembly.
      Fig 32: Identifying Front Door Inside Locking Cable Assembly
      G05252793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a "TORX" socket wrench (T30), loosen the screw.
    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
      G05756013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DOOR LOCK OPEN ROD 
    1. Remove the front door lock open rod as shown in the illustration.
    Fig 34: Removing Front Door Lock Open Rod
    G05756014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE DOOR ELECTRICAL KEY OSCILLATOR  (See REMOVAL )
  35. REMOVE OUTER MIRROR PROTECTOR  (See REMOVAL )
  36. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY  (See REMOVAL )
  37. REMOVE FRONT DOOR CHECK COVER 
    1. Remove the front door check cover.
      Fig 35: Identifying Front Door Check Cover
      G05321215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts, and front door check assembly.
      Fig 36: Identifying Front Door Check Assembly, Bolts And Nuts
      G05321216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 21 clips.
    2. Remove the double-sided tape and the front door weatherstrip.
    Fig 37: Identifying Front Door Weatherstrip And Clips
    G05321217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE FRONT DOOR FRAME COVER  (See REMOVAL )
  41. REMOVE FRONT DOOR BELT MOLDING ASSEMBLY  (See REMOVAL )
  42. REMOVE FRONT DOOR REAR WINDOW FRAME MOLDING  (See REMOVAL )
  43. REMOVE FRONT DOOR UPPER WINDOW FRAME MOLDING  (See REMOVAL )
scientia non olet · About LEMON Manuals