Front Door: Disassembly

1. Disengage the 2 clips and remove the front door lower frame bracket garnish.
   Fig 1: Identifying Front Door Lower Frame Bracket Garnish Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver with the tip wrapped with protective tape, disengage the 3 claws, and remove the front door inside handle bezel plug.
   Fig 2: Removing Front Door Inside Handle Bezel Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver with the tip wrapped with protective tape, disengage the 6 claws and remove the assist grip cover.
   Fig 3: Identifying Assist Grip Cover Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver with the tip wrapped with protective tape, disengage the claw and remove the courtesy light assembly.
2. Disconnect the connector.
   Fig 4: Identifying Courtesy Light Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 screws and clip (A).
   Fig 5: Identifying Front Door Trim Board Sub-Assembly Screws And Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a clip remover, disengage the 9 clips.
3. Pull up the front door trim board in the direction indicated by the arrow.
   Fig 6: Identifying Front Door Trim Board Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disengage 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.
6. Disengage the 2 claws and disconnect the front door inside handle sub-assembly.
   Fig 7: Identifying Front Door Inside Handle Sub-Assembly Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the connector.
2. Remove the 3 screws and the power window regulator master switch assembly.
   Fig 8: Identifying Power Window Regulator Master Switch Assembly Screws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disengage the clamp and remove the 2 screws and front door wire.
   Fig 9: Locating Front Door Wire Screws And Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, disengage the 4 clips as shown in the illustration and remove the front door inner glass weatherstrip from the front door trim board.
   Fig 10: Identifying Front Door Inner Glass Weatherstrip Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 7 screws.
2. Disengage the 4 claws and remove the front armrest base panel upper.
Fig 11: Locating Front Armrest Base Panel Upper Claws And Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the front door lock remote control cable and front door inside locking cable and remove the front door inside handle sub-assembly.
   Fig 12: Disconnecting Front Door Lock Remote Control Cable And Front Door Inside Locking Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the 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 Connector, Clamp And Front Door Service Hole Cover

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the front power window regulator motor assembly connector.
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.
3. Remove the 2 bolts.
   NOTE: After the bolts are removed, the door glass may fall, causing damage.
   Fig 14: Identifying Door Glass Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the front door glass sub-assembly as shown in the illustration.
   Fig 15: Removing Front Door Glass Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Do not damage the door glass.
5. Disconnect the power window regulator master switch assembly and front power window regulator motor assembly connector.

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, causing damage.

   Fig 16: Identifying Temporary Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 5 bolts.
3. Remove 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 front door window regulator sub-assembly.

1. Using a "TORX" driver (T25), remove the 3 screws and the front power window regulator motor assembly.
   Fig 17: Identifying Front Power Window Regulator Motor Assembly Screws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disengage the 2 claws.
2. Remove the double-sided tape and the front No. 1 door stiffener cushion.
   Fig 18: Identifying Front No. 1 Door Stiffener Cushion Double-Sided Tape

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the front door glass run.
   Fig 19: Identifying Front Door Glass Run

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disengage the clip and remove the door frame garnish.
   Fig 20: Identifying Door Frame Garnish Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 bolts and the front door front lower frame sub-assembly as shown in the illustration.
   Fig 21: Identifying Front Door Front Lower Frame Sub-Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and the front door rear lower frame sub-assembly as shown in the illustration.
   Fig 22: Identifying Front Door Rear Lower Frame Sub-Assembly Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 23: Removing Door Lock Key Cylinder Screw

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, disengage the 2 claws and remove the front door outside handle cover.
   Fig 24: Disengaging Front Door Outside Handle Cover Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the front door outside handle assembly as shown in the illustration.
   Fig 25: Identifying Front Door Outside Handle Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the connector.
   Fig 26: Locating Front Door Outside Handle Assembly Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the front door outside handle assembly as shown in the illustration.
   Fig 27: Identifying Front Door Outside Handle Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disengage the 3 claws and remove the front door front outside handle pad.
   Fig 28: Identifying Front Door Front Outside Handle Pad Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disengage the 2 claws and remove the front door rear outside handle pad.
   Fig 29: Identifying Front Door Rear Outside Handle Pad Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the connector.
2. Using a "TORX" socket wrench (T30), remove the 3 screws.
3. 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.
4. Remove the front door lock open rod from the front door lock assembly.
5. Remove the door lock wiring harness seal from the front door lock assembly.
   Fig 30: Identifying Front Door Lock Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the front door lock remote control cable assembly.
   Fig 31: Identifying Front Door Lock Remote Control Cable Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, disengage the 3 claws.

   HINT:

   Tape the screwdriver tip before use.

   Fig 32: Identifying Front Door Inside Locking Cable Assembly Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the front door inside locking cable assembly.
   Fig 33: Identifying Front Door Inside Locking Cable Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a "TORX" socket wrench (T30), remove the screw.
2. Disengage the claw and remove the front door outside handle frame sub-assembly.
   Fig 34: Identifying Front Door Outside Handle Frame Sub-Assembly Claw And Screw

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a "TORX" socket wrench (T30), remove 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 35: Identifying Front Door Outside Handle Frame Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the screw and door electrical key oscillator.
   Fig 36: Locating Door Electrical Key Oscillator Screw

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts and the front door check assembly.
   Fig 37: Identifying Front Door Check Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt, 2 nuts, and the front door check assembly.
   Fig 38: Identifying Front Door Check Assembly Bolt And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.
   Fig 39: Identifying Front Door Weatherstrip Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002