FRONT DOOR (for Hatchback without Power Window): Disassembly

HINT:

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

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
2. REMOVE DOOR WINDOW REGULATOR HANDLE ASSEMBLY 
   1. Insert a clip remover between the plate and door trim.
   2. Turn the handle with the clip remover inserted.
   3. Remove the front door window regulator handle and clip.
   4. Remove the window regulator handle plate.
      Fig 1: Turning Handle With Clip Remover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE DOOR ARMREST COVER 
   1. for 5 Door:

      Using a screwdriver with its tip wrapped in protective tape, disengage the 8 claws and 3 clips and remove the door armrest cover.

      Fig 2: Identifying Claws & Clips Location (5 Door)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. for 3 Door:

      Disengage the 12 claws and 4 clips and remove the door armrest cover.

      Fig 3: Identifying Claws & Clips Location (3 Door)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FRONT ARMREST BASE PANEL UPPER 
   1. Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws and clip and remove the front armrest base panel upper.
      Fig 4: Identifying Claws & Clips Location

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
   1. Remove the 4 screws.
      Fig 5: Locating Screws

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   2. for 5 Door:

      Disengage the 8 clips.

      Fig 6: Identifying Clips Location (5 Door)

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   3. for 3 Door:

      Disengage the 9 clips.

      Fig 7: Identifying Clips Location (3 Door)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Disconnect the front door lock remote control cable and front door inside locking cable and remove the front door trim board.
      Fig 8: Identifying Front Door Lock Remote Control Cable & Front Door Inside Locking Cable

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
   1. Disengage the 6 claws and remove the front door inside handle.
7. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER 
   1. Remove the front door glass weatherstrip inner from the front door trim board.
8. REMOVE FRONT NO.1 SPEAKER ASSEMBLY (See  REMOVAL  ) 
   Fig 9: Identifying Claws Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE FRONT DOOR WINDOW FRAME FRONT MOLDING (See  REMOVAL  ) 
10. REMOVE FRONT DOOR WINDOW FRAME REAR MOLDING (for 3 Door) (See  REMOVAL  ) 
11. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY (See  REMOVAL  ) 
12. REMOVE FRONT DOOR BELT MOLDING (See  REMOVAL  ) 
13. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. for 5 Door:

       Disconnect the connectors and clamps, then remove the front door service hole cover.

       NOTE: Remove any tape remaining on the door side.
       Fig 10: Identifying Front Door Service Hole Cover (5 Door)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for 3 Door:

       Disconnect the connectors and clamps, then remove the front door service hole cover.

       NOTE: Remove any tape remaining on the door side.
14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Provisionally install the front door window regulator handle.
       Fig 11: Identifying Front Door Service Hole Cover (3 Door)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Move the front door glass until the 2 bolts appear in the service holes.
    3. Remove the 2 bolts.
       NOTE: Do not drop or damage the front door glass when removing the 2 bolts.
       Fig 12: Locating Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front door glass in the direction indicated by the arrows.
       NOTE: Do not damage the glass.
    5. Remove the front door window regulator handle.
       Fig 13: Locating Front Door Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
       Fig 14: Locating Front Door Glass Run

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE FRONT DOOR WINDOW REGULATOR 
    1. Loosen bolt A.
    2. Remove the 4 bolts, then remove the front door window regulator.
       NOTE: Do not drop or damage the window regulator when removing the bolts.

       HINT:

       Remove the window regulator through the service hole.

       Fig 15: Locating Front Door Window Regulator Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the 3 bolts, 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 16: Locating Front Door Check Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE FRONT DOOR WEATHERSTRIP 
    1. for 5 Door:

       Disengage the 35 clips and remove the front door weatherstrip.

       NOTE: Remove any tape remaining on the door side.
       Fig 17: Identifying Clips Location (5 Door)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for 3 Door:

       Disengage the 37 clips and remove the front door weatherstrip.

       NOTE: Remove any tape remaining on the door side.
       Fig 18: Identifying Clips Location (3 Door)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER 
    1. Remove the bolt, then remove the front door frame sub-assembly rear lower.
       NOTE: Do not drop or damage the front door frame sub-assembly rear lower when removing the bolt.

       HINT:

       Remove the front door frame sub-assembly rear lower through the service hole.

       Fig 19: Locating Front Door Frame Sub-Assembly Rear Lower Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER 
    1. Remove the 2 bolts 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 bolts and screw.

       HINT:

       Remove the front door frame sub-assembly front lower through the service hole.

       Fig 20: Locating Front Door Frame Sub-Assembly Front Lower Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE FRONT DOOR FIX WINDOW WEATHERSTRIP 
    1. Slide the front door fix window weatherstrip, in the direction indicated by the arrow, to remove it.
    2. Remove the front door fix window glass from the front door fix window weatherstrip.
       Fig 21: Sliding Front Door Fix Window Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 22: Identifying Door Lock Key Cylinder

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE FRONT DOOR LOCK ASSEMBLY 
    1. Using "Torx" socket wrench T30, remove the 3 screws.
    2. Move the front door lock downward, remove the outside handle frame link and remove the front door lock.
       NOTE: Do not drop or damage the door lock when removing the screws.

       HINT:

       Remove the front door lock through the service hole.

       Fig 23: Locating "Torx" Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 5 claws and open the cover.
       Fig 24: Locating Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the front door lock remote control cable and front door inside locking cable.
    5. Remove the door lock wire harness seal.
       Fig 25: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE 
    1. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark.
       Fig 26: Pulling Front Door Handle Assembly Outside

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR 
    1. Disengage the 2 claws and remove the front door outside handle pad rear.
       Fig 27: Identifying Claws Location (1 Of 2)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. REMOVE FRONT DOOR OUTSIDE HANDLE PAD FRONT 
    1. Disengage the 2 claws and remove the front door outside handle pad front.
       Fig 28: Identifying Claws Location (2 Of 2)

       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 outside handle frame to remove it.
28. REMOVE CUSHION 
    1. Remove the 2 cushions from the door panel.
       Fig 29: Locating "Torx" Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. REMOVE FRONT DOOR STIFFENER CUSHION 
    1. Remove the bolt and front door stiffener cushion.
       Fig 30: Locating Front Door Stiffener Cushion Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002