Front Door: Disassembly

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Use the same procedures for the LH side and RH side.
The procedures for the LH side and RH side.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
REMOVE FRONT DOOR FRAME BRACKET GARNISH LOWER
1. Using a screwdriver, remove the lower frame bracket garnish.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 1: Removing Lower Frame Bracket Garnish
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
1. Using a screwdriver, remove the power window switch as shown in Fig 2.
  HINT:
  
  Tape the screwdriver tip before use.
2. Disconnect the connector.
  
  Fig 2: Removing Power Window Switch Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 DOOR INSIDE HANDLE BEZEL
1. Using a screwdriver, remove the No. 2 door inside handle bezel as shown in Fig 3.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 3: Removing No. 2 Door Inside Handle Bezel Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 DOOR INSIDE HANDLE BEZEL
1. Remove the screw.
2. Using a screwdriver, remove the No. 1 door inside handle bezel as shown in Fig 4.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 4: Removing No. 1 Door Inside Handle Bezel Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR COURTESY LIGHT ASSEMBLY
1. Using a screwdriver, remove the door courtesy light, then disconnect the connector.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 5: Removing Door Courtesy Light Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY
1. Remove the 2 caps and 7 screws.
2. Remove the 3 clips.
3. Insert a screwdriver between the door and the door trim to pry the trim.
  NOTE: Be careful not to damage the door and the door trim.
  
  HINT:
  
  Tape the screwdriver tip before use.
4. Pull the trim upward to remove it.
  
  Fig 6: Removing Front Door Trim Board Subassembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY
1. Remove the screw and inside handle.
2. Disconnect the 2 control cables from the inside handle as shown in Fig 7.
Fig 7: Disconnecting Control Cables From Inside Handle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 2 SPEAKER ASSEMBLY
1. Disconnect the connector, and then remove the bolt and the tweeter speaker.
REMOVE OUTER REAR VIEW MIRROR ASSEMBLY
1. Disconnect the connector, and then remove the 3 bolts and outside rear view mirror.
REMOVE FRONT DOOR SERVICE HOLE COVER
1. Remove the clamps and wire harness.
2. Remove the service hole cover.
  NOTE: Do not tear the cover.
  
  HINT:
  
  At the time of reassembly, pull out the 2 control cables and wire harness through the service hole cover.
  
  Fig 8: Removing Clamps & Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR BELT MOLDING ASSEMBLY
1. Remove the screw.
2. Using a scraper, remove the door belt molding.
  HINT:
  
  Tape the screwdriver tip before use.
Fig 9: Removing Door Belt Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR GLASS SUB-ASSEMBLY
1. Open the door glass until the bolts appear in the service hole.
2. Remove the 2 bolts and the door glass.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  NOTE: Do not damage the door glass.
  
  HINT:
  
  Pull the glass upward to remove it.
REMOVE FRONT NO. 1 DOOR SPEAKER ASSEMBLY
1. Remove the 3 screws and speaker, and then disconnect the connector.
REMOVE FRONT DOOR GLASS RUN
REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER
1. Remove the bolt and frame sub-assembly rear lower.
REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
1. Disconnect the connector, and then remove the 5 bolts for bolt B.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
2. Loosen the bolt and the window regulator for bolt A.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 10: Removing Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - Remove the regulator through the service hole.
  - At the time of reassembly, apply MP grease to the window regulator.
    
    Fig 11: Applying MP Grease To Window Regulator
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE: At the time of reassembly, do not apply grease to the spring of the window regulator.
REMOVE FRONT DOOR LOCK ASSEMBLY
1. Remove the clip and the door lock link protector.
2. Disconnect the connector.
3. Disconnect the 2 links from the outside handle and door lock cylinder.
4. Using a "torx" wrench, remove the 3 screws and the door lock through the service hole.
  - "Torx" wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
  - Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
  Fig 12: Removing Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  At the time of reassembly:
  - Apply adhesive to the 3 screws.
    Adhesive:
    
    Part No. 08833-00070, THREE BOND 1324 or equivalent.
  - Remove the protector, and apply MP grease to the sliding and rotating parts of the door lock.
  Fig 13: Applying MP Grease To Sliding & Rotating Parts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTSIDE HANDLE WITH DOOR LOCK CYLINDER
1. Remove the 2 bolts and outside handle with the door lock cylinder.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Remove the bolt and door lock cylinder from the outside handle.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)