FRONT DOOR (for Sedan): 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 FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window) 
   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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
   1. Disengage the claw and clip and remove the front door lower frame bracket garnish.
      Fig 2: Identifying Claw & Clip Location

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FRONT ARMREST BASE UPPER PANEL 
   1. for Driver side with power window:
      1. Remove the screw.
      2. Disengage the 7 claws and 2 clips and remove the front armrest base upper panel.
      3. Disconnect the connector.
         Fig 3: Identifying Claws & Clips Location (Driver Side With Power Window)

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. for Front passenger side with power window:
      1. Remove the screw.
      2. Disengage the 7 claws and 2 clips and remove the front armrest base upper panel.
      3. Disconnect the connector.
         Fig 4: Identifying Claws & Clips Location (Front Passenger Side With Power Window)

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. w/o Power window:
      1. Remove the screw.
      2. Disengage the 5 claws and 2 clips and remove the front armrest base upper panel.
         Fig 5: Identifying Claws & Clips Location (Without Power Window)

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Power Window) 
   1. Remove the 3 screws and the power window regulator master switch.
      Fig 6: Locating Power Window Regulator Master Switch Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/ Power Window) 
   1. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the power window regulator switch.
      Fig 7: Identifying Claws Location (1 Of 2)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE DOOR CONTROL SWITCH (w/ Power Door Lock) 
   1. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the door control switch.
      Fig 8: Identifying Claws Location (2 Of 2)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
   1. w/ Power window:
      1. Remove the screw.
         Fig 9: Locating Screw

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage the 9 clips.
         Fig 10: Identifying Clips Location

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the front door lock remote control cable and front door inside locking cable and remove the front door trim board.
         Fig 11: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. w/o Power window:
      1. Remove the screw.
         Fig 12: Locating Screw

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage the 9 clips.
         Fig 13: Identifying Clips Location

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the front door lock remote control cable and front door inside locking cable and remove the front door trim board.
         Fig 14: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
   1. Using a screwdriver with its tip wrapped in protective tape, disengage the 4 claws and remove the front door inside handle.
10. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER 
    1. Remove the front door glass weatherstrip inner from the front door trim board.
11. REMOVE FRONT NO.1 SPEAKER ASSEMBLY (See  REMOVAL  ) 
    Fig 15: Identifying Claws Location

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE OUTER REAR VIEW MIRROR (See  REMOVAL  ) 
13. REMOVE FRONT DOOR BELT MOLDING (See  REMOVAL  ) 
14. REMOVE FRONT DOOR TRIM BRACKET 
    1. Remove the 2 screws and front door trim bracket.
       Fig 16: Locating Front Door Trim Bracket Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Disconnect the connectors and clamps, then remove the front door service hole cover.
       NOTE: Remove any tape remaining on the door side.
16. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. w/ Power window:
       1. Driver side:

          Provisionally install the power window regulator master switch.

       2. Passenger side:

          Provisionally install the power window regulator switch.

          Fig 17: Identifying Front Door Service Hole Cover

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o Power window:
       1. Provisionally install the front door window regulator handle.
    3. Move the front door glass until the 2 bolts can be seen through the service holes.
    4. Remove the 2 bolts.
       NOTE: Do not drop or damage the front door glass when removing the bolts.
       Fig 18: Locating Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the front door glass in the direction indicated by the arrows in Fig 19 .
       NOTE: Do not damage the glass.
    6. w/ Power window:
       1. Driver side:

          Remove the power window regulator master switch.

       2. Passenger side:

          Remove the power window regulator switch.

    7. w/o Power window:
       1. Remove the front door window regulator handle.
          Fig 19: Identifying Front Door Glass

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. w/ Power window:
       1. Disconnect the connector.
       2. Loosen bolt A.
       3. Remove the 5 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 20: Locating Front Door Window Regulator Bolts (With Power Window)

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o Power window:
       1. Loosen bolt A.
       2. Remove the 5 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 21: Locating Front Door Window Regulator Bolts (Without Power Window)

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT (w/ Power Window) 
    1. Using "Torx" socket wrench T25, remove the 3 screws and power window regulator motor.
       Fig 22: Locating Screws & Power Window Regulator Motor

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE FRONT DOOR GLASS RUN 
    1. Disengage the clip, then remove the front door glass run.
       Fig 23: Locating Front Door Glass Run

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. 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 24: Locating Front Door Frame Sub-Assembly Rear Lower Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER 
    1. Remove the bolt, 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.

       HINT:

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

       Fig 25: Locating Front Door Frame Sub-Assembly Front Lower Bolt

       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 26: Identifying Door Lock Key Cylinder

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE FRONT DOOR LOCK 
    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 front door lock when removing the screws.

       HINT:

       Remove the front door lock through the service hole.

       Fig 27: Locating Front Door Lock Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Open the cover.
       Fig 28: 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 29: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable

       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 30 .
       Fig 30: Pulling Handle

       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 31: 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 32: 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 front outside handle frame to remove it.
       Fig 33: Locating "Torx" Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. REMOVE DOOR OUTSIDE HANDLE PROTECTOR 
    1. Slide the door outside handle protector to remove it.
       Fig 34: Sliding Door Outside Handle Protector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. 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 35: Identifying Front Door Check Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Disengage the 35 clips and remove the front door weatherstrip.
       NOTE: Remove any tape remaining on the door side.
       Fig 36: Identifying Clips & Front Door Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. REMOVE FRONT DOOR STIFFENER CUSHION 
    1. Remove the bolt and front door stiffener cushion.
       Fig 37: Locating Front Door Stiffener Cushion Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. REMOVE CUSHION 
    1. Remove the 2 cushions from the door panel.
       Fig 38: Locating Cushions

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002