Front Door: Disassembly

HINT:

• Use the same procedure for both the RH and LH sides.
• The procedure described below is for the RH side.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
2. REMOVE FRONT ARMREST BASE UPPER PANEL 
   1. Disengage the 3 claws and clip and remove the front armrest base upper panel.
      Fig 1: Identifying Front Armrest Base Upper Panel Claws & Clip

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Disconnect the connector.
3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)  (See REMOVAL )
4. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)  (See REMOVAL )
5. REMOVE DOOR CONTROL SWITCH (for Front Passenger Side)  (See REMOVAL )
6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
   1. for LH side:

      Using a screwdriver with its tip wrapped in protective tape, open the 2 covers.

      Fig 2: Identifying Covers (For LH Side)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. for RH side:

      Using a screwdriver with its tip wrapped in protective tape, open the 2 covers.

      Fig 3: Identifying Covers (For RH Side)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Remove the 2 screws.
      Fig 4: Identifying Front Door Trim Board Sub-Assembly Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Disengage the 10 clips.
      Fig 5: Identifying Front Door Trim Board Sub-Assembly Clips

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Disconnect the front door lock remote control cable and front door inside locking cable and remove the front door trim board.
      Fig 6: Identifying Front Door Lock Remote Control Cable & Inside Locking Cable

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE FRONT NO. 2 DOOR SERVICE HOLE COVER 
   1. Remove the 4 screws and front No. 2 door service hole cover.
      Fig 7: Identifying Front No. 2 Door Service Hole Cover Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE OUTER REAR VIEW MIRROR 

   HINT:

   Use the same procedure as for the LH side (see REMOVAL ).

9. REMOVE FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY 

   HINT:

   Use the same procedure as for the LH side (See REMOVAL ).

10. REMOVE FRONT NO. 1 SPEAKER  (See REMOVAL )
11. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Remove the front door service hole cover.
       NOTE: Remove any tape remaining on the door side.
       Fig 8: Identifying Front Door Service Hole Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE FRONT DOOR INSIDE PANEL PLATE 
    1. Remove the 4 screws and the front door inside panel plate.
       Fig 9: Identifying Front Door Inside Panel Plate Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the 2 nuts and bolt, then remove the front door check.
       NOTE: Do not drop or damage the door check when removing the bolts.

       HINT:

       Remove the door check through the service hole.

       Fig 10: Identifying Front Door Check Nuts & Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Disengage the 24 clips and remove the front door weatherstrip.
       NOTE: Remove any tape remaining on the door side.
       Fig 11: Identifying Front Door Weatherstrip Clips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
       Fig 12: Identifying Front Door Glass Run

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER 
    1. Remove the hole plug.
       Fig 13: Identifying Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and screw, then remove the front door frame sub-assembly front lower.
       NOTE: Do not drop or damage the front door frame sub-assembly front lower when removing the bolt and screw.
       Fig 14: Identifying Front Door Frame Sub-Assembly Front Lower Bolt & Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Remove the bolt and the 2 screws and remove front door lower frame bracket garnish.
       Fig 15: Identifying Front Door Lower Frame Bracket Garnish Bolt & Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE FRONT DOOR WINDOW FRAME REAR LOWER 
    1. Remove the bolt, then remove the front door window frame rear lower.
       NOTE: Do not drop or damage the front door window frame rear lower when removing the bolt.
       Fig 16: Identifying Front Door Window Frame Rear Lower Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the hole plug.
       Fig 17: Identifying Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Driver side:

       Provisionally install the power window regulator master switch.

    3. Passenger side:

       Provisionally install the power window regulator switch.

    4. Move the front door glass until the 2 bolts can be seen through the service holes.
    5. Remove the 2 bolts.
    6. Pull the door glass upward to remove it.
       NOTE: Do not damage the glass.
    7. Driver side:

       Remove the power window regulator master switch.

    8. Passenger side:

       Remove the power window regulator switch.

       Fig 18: Identifying Front Door Glass Sub-Assembly Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the 6 bolts, then remove the front door window regulator.
       NOTE: Do not drop or damage the front door window regulator.

       HINT:

       Remove the window regulator through the service hole.

       Fig 19: Identifying Front Door Window Regulator Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY  (See REMOVAL )
22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER 
    1. Remove the hole plug.
    2. Using "Torx" socket wrench T30, loosen the screw and remove the cover with the door lock key cylinder installed.
       Fig 20: Loosening Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the front door outside handle cover.
23. REMOVE FRONT DOOR LOCK  (See REMOVAL )
    Fig 21: Identifying Front Door Outside Handle Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in Fig 22.
       Fig 22: Identifying Front Door Outside Handle Assembly Position

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE FRONT DOOR OUTSIDE HANDLE REAR PAD 
    1. Disengage the 2 claws and remove the front door outside handle rear pad.
       Fig 23: Identifying Front Door Outside Handle Rear Pad Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. REMOVE FRONT DOOR OUTSIDE HANDLE FRONT PAD 
    1. Disengage the 3 claws and remove the front door outside handle front pad.
       Fig 24: Identifying Front Door Outside Handle Front Pad Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using "Torx" socket wrench T30, loosen the screw.
    2. Slide the front door outside handle frame to remove it.

       HINT:

       Remove the front door outside handle frame through the service hole.

       Fig 25: Identifying Front Door Outside Handle Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. REMOVE FRONT DOOR OUTSIDE MOLDING SUB-ASSEMBLY 

    HINT:

    Use the same procedure as for the LH side (see REMOVAL ).

29. REMOVE CUSHION 
    1. Remove the 2 cushions.
       Fig 26: Identifying Cushions

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002