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Home >> Lexus >> 2021 >> IS 350 RWD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) - Service Information (1 Of 2) >> Front Door >> Disassembly [10/2016 - 09/2020] >> Procedure

Disassembly [10/2016 - 09/2020]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [10/2016 - 10/2017] , or refer to PRECAUTION [10/2017 - 09/2020]

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    WARNING:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery 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 [10/2016 - 10/2017] , or refer to INITIALIZATION [10/2017 - 09/2020]

  3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a moulding remover, disengage the 3 claws to remove the front door inside handle bezel plug.
      GTY469256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) 
    1. Using a moulding remover, disengage the 2 clips, 7 claws and 6 guides.
      GTY459407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector to remove the multiplex network master switch assembly with front door armrest base panel.
  5. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) 
    1. Using a moulding remover, disengage the 2 clips, 7 claws and 6 guides.
      GTY459406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector to remove the power window regulator switch assembly with front door armrest base panel.
  6. REMOVE FRONT DOOR ARMREST COVER 
    1. Using a moulding remover, disengage the 2 claws.
      GTY469257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 guides to remove the front door armrest cover.
  7. REMOVE COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE FRONT DOOR NO. 1 STIFFENER CUSHION 
    1. Remove the screw and front door No. 1 stiffener cushion.
      GTY459469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Put protective tape around the front door panel.
      GTY459403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 screws.
      GTY459401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a clip remover, disengage the 9 clips.
    4. Pull out the front door trim board sub-assembly as shown in the illustration.
      GTY457409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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. Disconnect each connector.
    8. 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.
      GTY459471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. remove the 6 screws.
      GTY459397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 3 guides, and remove the front door inside handle sub-assembly.
  11. REMOVE FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 9

  12. REMOVE SEAT MEMORY SWITCH (w/ Memory) 

    Refer to PROCEDURE - Step 2

  13. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    GTY469822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *a Screwdriver
    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.
  14. REMOVE DOOR SIDE AIRBAG SENSOR (w/ Occupant Classification System) 

    Refer to PROCEDURE - Step 10

  15. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) 

    Refer to PROCEDURE - Step 9

  16. REMOVE OUTER MIRROR PROTECTOR 

    Refer to PROCEDURE - Step 12

  17. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 13

  18. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Disengage the 2 clips and remove the front door lower frame bracket garnish.
      GTY459399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Remove the front door service hole cover.
      GTY469240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Remove any remaining butyl tape from the front door panel.

  20. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  21. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Connect the cable to the negative (-) battery terminal.
    2. for Driver Side:
      1. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
    3. for Front Passenger Side:
      1. Connect the power window regulator 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 negative (-) battery terminal.
      WARNING:

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

    5. for Driver Side:
      1. Disconnect the multiplex network master switch assembly.
    6. for Front Passenger Side:
      1. Disconnect the power window regulator switch assembly.
    7. Remove the 2 bolts.
      GTY459394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    8. Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.
      Fig 1: Front Door Glass Sub-Assembly Removal Sequence [10/2016 - 09/2020]
      GTY469616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the front door glass sub-assembly.

  22. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Disconnect the connector.
    2. Loosen the temporary bolt.
      GTY469379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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.

    3. Remove the 5 bolts.
    4. Remove the front door window regulator assembly.
    5. Remove the temporary bolt from the front door window regulator assembly.
  23. 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 from the front door window regulator sub-assembly.
      GTY459558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR NO. 2 STIFFENER CUSHION 
    1. Remove the 2 bolts.
      GTY459559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and remove the front door No. 2 stiffener cushion.
  25. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
      GTY459556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the bolt.
      GTY459557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and remove the front door rear lower frame sub-assembly.
  27. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
      GTY459562Courtesy 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.
      GTY459563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  28. 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 from the lock cylinder assembly.
      GTY459560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Remove the hole plug.
      GTY459561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.
      GTY469277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  30. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Disengage the 2 claws.
      GTY459564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disconnect the connector.
    3. Move the lever in the direction as shown in the illustration.
      GTY459565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front door outside handle assembly as shown in the illustration.
      GTY459582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws to remove the front door front outside handle pad.
      GTY469281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws to remove the front door rear outside handle pad.
      GTY459583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY 
    1. Disconnect the connector.
    2. Using a T30 "TORX" socket wrench, remove the 3 screws.
      GTY464906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Lock Open Rod
    3. Slide the front door lock with motor assembly downward to disconnect the front door lock open rod and remove the front door lock with motor assembly and cables as a unit.
    4. When reusing the front door lock with motor assembly:
      1. Remove the door lock wire harness seal from the front door lock with motor assembly.
        GTY459530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 2 claws as shown in the illustration.
      GTY459580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door lock remote control cable assembly as shown in the illustration.
      GTY459532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Remove the front door inside locking cable assembly as shown in the illustration.
      GTY469270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY462638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Outside
      *B Inside
    2. Slide the front door outside handle frame sub-assembly to disengage the claw and separate the front door outside handle frame sub-assembly.
    3. Pull back the front door outside handle frame sub-assembly from the front door panel.
    4. Disengage the 3 clamps and remove the front door outside handle frame sub-assembly
      GTY465427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE FRONT DOOR LOCK OPEN ROD 
    Fig 2: Front Door Lock Open Rod Removal Sequence [10/2016 - 09/2020]
    GTY460242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.
  38. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the 2 nuts and bolt, and front door check assembly.
      GTY459573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 21 clips and remove the front door weatherstrip.
      GTY469279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE DOOR FRAME GARNISH 
    1. Disengage the 3 claws to remove the door frame garnish.
      GTY459571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Using a clip remover, disengage the 8 clips and remove the front door No. 2 weatherstrip.
      GTY459572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT DOOR PANEL CUSHION 
    GTY469278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disengage the claw and remove the front door panel cushion.
  43. REMOVE FRONT DOOR PANEL PROTECTOR 
    1. Remove the front door panel protector.
      GTY666312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE FRONT DOOR FRONT LOWER FRAME UPPER COVER 

    Refer to PROCEDURE - Step 10

  45. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 16

  46. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 5

  47. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 6

  48. REMOVE FRONT DOOR INNER UPPER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 6

  49. REMOVE FRONT DOOR REAR INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 7

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