Front Door: Disassembly

HINT:

• Use the same procedures for the LH side and RH side.
• The procedures listed below are for the LH side.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
   CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
   1. Using a screwdriver, detach the clip, 3 claws and remove the garnish.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Detaching Clip And Front Door Lower Frame Bracket Garnish LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT ARMREST BASE UPPER PANEL LH 
   1. Using a screwdriver, detach the clip, 5 claws, and remove the panel (with the switch).

      HINT:

      Tape the screwdriver tip before use.

   2. Disconnect the switch connectors.
      Fig 2: Detaching Clip Front Armrest Base Upper Panel LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. for Driver Side: Remove the 3 screws and power window regulator master switch from the panel.
      NOTE: Be careful when removing the screws as the switch may fall and become damaged.
      Fig 3: Removing Screws And Power Window Regulator Master Switch From Panel

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. for Passenger Side: Using a screwdriver, detach the 2 claws and remove the door control switch from the panel.

      HINT:

      Tape the screwdriver tip before use.

      NOTE: Be careful when detaching the claws as the switch may fall and become damaged.
      Fig 4: Detaching Claws And Door Control Switch From Panel

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. for Passenger Side: Using a screwdriver, detach the 2 claws and remove the power window regulator switch from the panel.

      HINT:

      Tape the screwdriver tip before.

      NOTE: Be careful when detaching the claws as the switch may fall and become damaged.
      Fig 5: Detaching Claws And Power Window Regulator Switch From Panel

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH 

   Using a screwdriver, detach the 12 claws and remove the door assist grip.

   Fig 6: Detaching Claws And Door Assist Grip Using Screwdriver

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Tape the screwdriver tip before use.

   Using a screwdriver, detach the 3 claws and remove the door inside handle plug.

   HINT:

   Tape the screwdriver tip before use.

   Fig 7: Detaching Claws And Door Inside Handle Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Remove the 3 screws (see Fig 8).
   2. Using a screwdriver, detach the 10 clips, 2 claws and remove the trim.

      HINT:

      • Tape the screwdriver tip before use.
      • If the screwdriver cannot reach the clips, pull on the lower trim to remove it.
   3. Using a screwdriver, detach the 7 claws and remove the weatherstrip inner.

      HINT:

      Tape the screwdriver tip before use.

   4. Using a screwdriver, detach the 4 claws and remove the speaker door grille.

      HINT:

      Tape the screwdriver tip before use.

      Fig 8: Removing Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (See appropriate step(s) under  REMOVAL  ) 
6. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See appropriate step(s) under  REMOVAL  ) 
7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (See appropriate step(s) under  REMOVAL  ) 
8. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH 
   1. Disconnect the 2 cables from the inside handle and remove the inside handle.
      Fig 9: Disconnecting Cables From Inside Handle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
   1. Disconnect each connector and remove the service hole cover.
      NOTE: Remove the remaining tape on the door.
      Fig 10: Removing Front Door Service Hole Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH (See appropriate step(s) under  REMOVAL  ) 
11. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH 
    1. for Driver Side: Temporarily install the power window regulator master switch.
    2. for Passenger Side: Temporarily install the power window regulator switch.
    3. Move the door glass until the 2 bolts appear in the service holes.
    4. Remove the 2 bolts.
       NOTE: Be careful when removing the bolts as the glass may fall and become damaged.
       Fig 11: Removing Door Glass Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the door glass in the direction indicated by the arrows in Fig 12.

       HINT:

       Remove the glass upward.

       NOTE: Be careful not to damage the glass.
    6. Driver side: Remove the power window regulator master switch.
    7. Passenger side: Remove the power window regulator switch.
       Fig 12: Removing Door Glass In Direction

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 
    1. Disconnect the connector.
    2. Remove the 6 bolts and regulator.

       HINT:

       Remove the window regulator through the service hole.

       NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.
       Fig 13: Removing Bolts And Front Door Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 
    1. Using a T25 "Torx" driver, remove the 3 screws and motor.
       NOTE: Be careful when removing the screws as the motor may fall and become damaged.
       Fig 14: Removing Screws And Power Window Regulator Motor

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DOOR LOWER REAR FRAME SUBASSEMBLY LH 
    1. Remove the bolt.

       HINT:

       Remove the frame through the service hole.

       NOTE: Be careful when removing the bolts as the frame may fall and become damaged.
       Fig 15: Removing Front Door Lower Rear Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH (for Driver Side) 
    1. Remove the hole plug.
    2. Using a T30 "Torx" socket, loosen the screw and remove the cover (with door lock cylinder).

       HINT:

       Loosen but do not remove the screw.

    3. Remove the door lock cylinder from the cover.
       Fig 16: Removing Front Door Outside Handle Cover (Driver Side)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH (for Front Passenger Side) 
    1. Remove the hole plug.
    2. Using a T30 "Torx" socket, loosen the screw and remove the cover.

       HINT:

       Loosen but do not remove the screw.

       Fig 17: Removing Front Door Outside Handle Cover (Front Passenger Side)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE FRONT DOOR LOCK ASSEMBLY LH 
    1. Disconnect the connector.
    2. Using a T30 "Torx" socket, remove the 3 screws.
       NOTE: Be careful when removing the bolts as the door lock may fall and become damaged.
       Fig 18: Removing Screws And Front Door Lock Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Slide the door lock downward to disconnect the front door lock open rod from the door lock. Then remove the door lock (with cable).
       Fig 19: Sliding Door Lock Downward

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       Remove the door lock through the service hole.

    4. Remove the door lock wiring harness packing from the door lock.
       Fig 20: Removing Door Lock Wiring Harness Packing From Door Lock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver, detach the 3 claws and open the cover.

       HINT:

       Tape the screwdriver tip before use.

       Fig 21: Detaching Claws And Open Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 cables as shown in the illustration.
       Fig 22: Removing Cables From Door Lock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH 
    1. Remove the handle by sliding and pulling it in the direction indicated by the arrow in the illustration.
       Fig 23: Removing Front Door Outside Handle Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Using a T30 "Torx" socket, loosen the screw of the frame.
       Fig 24: Loosening Screw On Front Door Outside Handle Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using pliers, pinch the clip.
       NOTE: Be sure to remove the outside handle frame together with the clip, as the clip will be damaged if it remains attached to the door panel.
       Fig 25: Removing Outside Handle Frame Together With Clip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Detach the claw and remove the frame.

       HINT:

       Remove the frame through the service hole.

    4. Remove the front door lock open rod.
       Fig 26: Detaching Claw And Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE FRONT DOOR OUTSIDE HANDLE FRONT PAD 
    1. Detach the 2 claws and remove the pad.
       Fig 27: Detaching Claws And Front Door Outside Handle Front Pad

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE FRONT DOOR OUTSIDE HANDLE REAR PAD 
    1. Detach the 2 claws and remove the pad.
       Fig 28: Detaching Claws And Front Door Outside Handle Rear Pad

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE FRONT DOOR CHECK ASSEMBLY LH 
    1. Remove the 3 bolts and door check.
       Fig 29: Removing Bolts And Door Check

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       Remove the door check through the service hole.

23. REMOVE FRONT DOOR GLASS RUN LH 
24. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a clip remover, detach the 17 clips and remove the weatherstrip.
       Fig 30: Detaching Clips And Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       If clips are damaged during removal, replace them.

25. REMOVE CUSHION 
    1. Remove the 2 cushions.