Front Door: Disassembly

REMOVE FRONT DOOR INSIDE HANDLE BEZEL
1. Remove the screw.
2. Using a screwdriver with its tip taped, disengage the 2 claws A.
  
  Fig 1: Identifying 2 Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Pull out the front door inside handle bezel in the direction indicated by the arrow, disengage the claw B, and remove the front door inside handle bezel.
REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY
1. Using a screw driver wrapped with the protective tape, disengage the 5 claws and clip.
2. Disconnect the connector and remove the multiplex network master switch assembly.
  
  Fig 2: Identifying 5 Claws And Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR PULL HANDLE
1. Using a screw driver wrapped with the protective tape, disengage the 2 clips and remove the door pull handle.
  
  Fig 3: Identifying Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH
1. Disengage the claw and the clip, and remove the front door lower frame bracket garnish.
  
  Fig 4: Identifying Claw, Clip, And Front Door Lower Frame Bracket Garnish
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY
1. Remove the screw and the clip.
2. Disengage the 7 clips and pull up on the front door trim board sub-assembly to remove it.
  
  Fig 5: Identifying 7 Clips And Front Door Trim Board Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Remove the bolt.
2. Disengage the 2 claws and separate the front door inside handle sub-assembly.
3. Disconnect the 2 cables and remove the front door inside handle sub-assembly.
REMOVE FRONT NO.1 SPEAKER (See REMOVAL )
REMOVE FRONT NO.2 SPEAKER (See INSTALLATION )
REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See PARTS LOCATION )
REMOVE FRONT DOOR SERVICE HOLE COVER
1. Remove the front door service hole cover.
  NOTE: Remove the remaining tape on the door side.
  
  Fig 7: Identifying Front Door Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR GLASS RUN
1. Connect the multiplex network master switch assembly.
2. Fully lower the front door glass sub-assembly.
3. Remove the front door glass run.
REMOVE FRONT DOOR GLASS SUB-ASSEMBLY
1. Move the front door glass sub-assembly so that the door glass bolts can be seen.
2. Remove the 2 bolts and front door glass sub-assembly.
  NOTE: After the bolts are removed, the door glass may fall and became deformed.
  
  Fig 8: Identifying Front Door Glass Sub-Assembly With 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the multiplex network master switch assembly.
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.
  
  Fig 9: Identifying Temporary Bolt To Front Door Window Regulator Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 5 bolts and the front door window regulator sub-assembly and the power window regulator motor assembly front as a unit.
4. Remove the temporary bolt from the regulator.
REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT
1. Using a "Torx" driver (T25), remove the 3 screws and power window regulator motor assembly front.
  
  Fig 10: Locating Front Door Window Regulator Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER
1. Remove the bolt.
2. Pull out the direction indicated by the arrow, remove the front door frame sub-assembly rear lower.
  
  Fig 11: Locating Front Door Frame Sub-Assembly Rear Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR LOCK ASSEMBLY
1. Disconnect the connector.
2. Remove the bolt.
3. Using a "Torx" socket wrench (T30), remove the 3 screws.
4. Separate the 2 link rods and remove the front door lock assembly and cables as a unit.
  
  Fig 12: Identifying Front Door Outside Handle Link Rods To Front Door Lock Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE COVER
1. Remove the hole plug.
2. Using a "Torx" socket wrench (T30), loosen the screw.
  HINT:
  
  Loosen but do not remove the screw.
3. Remove the front door outside handle cover as shown in the illustration.
  
  Fig 14: Locating Front Door Outside Handle Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE
1. Remove the front door handle assembly outside as shown in the illustration.
  
  Fig 15: Locating Front Door Handle Assembly Outside
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE PAD
1. Disengage the 2 claws and remove the front door outside handle pad.
  
  Fig 16: Identifying 2 Claws And Front Door Outside Handle Pad
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR
1. Disengage the 2 claws and remove the front door outside handle pad rear.
  
  Fig 17: Identifying 2 Claws And Front Door Outside Handle Pad Rear
  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:
  
  Loosen but do not remove the screw.
  
  Fig 18: Locating Front Door Outside Handle Frame Sub-Assembly With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disengage the claw.
  
  Fig 19: identifying Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disengage the clip and remove the front door outside handle frame sub-assembly.
  
  Fig 20: Identifying Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR CHECK ASSEMBLY
1. Remove the 3 bolts and front door check assembly.
  
  Fig 21: Identifying Front Door Check Assembly With 3 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WEATHERSTRIP
1. Disengage the 19 clips and remove the front door weatherstrip.
REMOVE FRONT DOOR BELT MOLDING ASSEMBLY (See INSTALLATION )