Front Door: Disassembly

DISCONNECT NEGATIVE BATTERY TERMINAL
CAUTION: Wait for 90 seconds after disconnecting the terminal to prevent airbag deployment (See PRECAUTION ).

NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH
1. Disengage the claw and clip, and remove the front door lower frame bracket garnish.
  
  Fig 1: Identifying Front Door Lower Frame Bracket Garnish Claw & Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG
1. Using a screwdriver with the tip wrapped with protective tape, disengage the 3 claws, and remove the front door inside handle bezel plug.
  
  Fig 2: Disengaging Front Door Inside Handle Bezel Plug Claws Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT ARMREST UPPER BASE PANEL
1. Using a screwdriver with the tip wrapped with protective tape, disengage the 7 claws and clip, and remove the front armrest upper base panel.
2. Disconnect the connector.
  
  Fig 3: Disengaging Front Armrest Upper Base Panel Claws & Clip Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)
1. Remove the 3 screws and the power window regulator master switch assembly.
  
  Fig 4: Identifying Power Window Regulator Master Switch Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)
1. Disengage the 2 claws and remove the power window regulator switch assembly.
  
  Fig 5: Identifying Power Window Regulator Switch Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side)
1. Disengage the 2 claws and remove the door control switch assembly.
  
  Fig 6: Identifying Door Control Switch Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ASSIST GRIP COVER
1. Using a screwdriver with the tip wrapped with protective tape, disengage the 4 claws and remove the assist grip cover.
  
  Fig 7: Identifying Assist Grip Cover Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COURTESY LIGHT ASSEMBLY
1. Using a screwdriver with the tip wrapped with protective tape, disengage the claw and remove the courtesy light assembly.
2. Disconnect the connector.
  
  Fig 8: Identifying Courtesy Light Assembly Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY
1. Remove the 3 screws.
  
  Fig 9: Identifying Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a clip remover, disengage the 9 clips.
3. Disengage the 5 claws and separate the front door trim board sub-assembly from the front door inner glass weatherstrip.
  
  Fig 10: Identifying Front Door Trim Board Sub-Assembly Clips & Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disengage the 2 clamps.
5. Disconnect the front door lock remote control cable and front door inside locking cable.
6. Disconnect the connector.
  
  Fig 11: Identifying Front Door Lock Remote Control Cable Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Remove the 2 screws.
2. Disengage the 2 claws and remove the front door inside handle sub-assembly.
  
  Fig 12: Locating Front Door Inside Handle Sub-Assembly Screws & Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WIRE (for Driver Side)
1. Disengage the 3 clamps and remove the front door wire.
  
  Fig 13: Identifying Front Door Wire Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP
1. Remove the front door inner glass weatherstrip from the front door panel.
  
  Fig 14: Identifying Front Door Inner Glass Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See REMOVAL )
REMOVE OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER (See REMOVAL )
REMOVE FRONT DOOR SERVICE HOLE COVER
1. Disconnect the each connector and 2 clamps, and remove the front door service hole cover.
  HINT:
  
  Remove the remaining butyl tape on the door side.
  
  Fig 15: Identifying Front Door Service Hole Cover Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR GLASS SUB-ASSEMBLY
1. Remove the hole plug.
2. Connect the negative battery terminal.
3. Connect the power window regulator motor connector.
4. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
  
  Fig 16: Identifying Front Door Glass Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the negative battery terminal and power window regulator master switch assembly.
6. Disconnect the power window regulator motor connector.
7. Remove the 2 bolts.
  NOTE: After the bolts are removed, do not allow the door to fall.
  
  Fig 17: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the front door glass sub-assembly as shown below.
  NOTE: Do not damage the door glass.
  
  Fig 18: Identifying Front Door Glass Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
1. Loosen the temporary bolt.
  NOTE: Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall and cause damage.
2. Remove the 5 bolts.
  
  Fig 19: Identifying Front Door Window Regulator Sub-Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the front door window regulator sub-assembly and the front power window regulator motor assembly as a unit.
4. Remove the temporary bolt from the front door window regulator sub-assembly.
REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY
1. Using a "TORX" driver (T25), remove the 3 screws and the front power window regulator motor assembly.
  
  Fig 20: Identifying Front Power Window Regulator Motor Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR GLASS RUN
1. Remove the front door glass run.
  
  Fig 21: Identifying Front Door Glass Run
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
1. Remove the bolt and the front door rear lower frame sub-assembly as shown below.
  
  Fig 22: Identifying Front Door Rear Lower Frame Sub-Assembly Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)
1. Remove the hole plug.
2. Using a "TORX" socket wrench (T30), loosen the screw and remove the front door outside handle cover and the door lock key cylinder as a unit.
  HINT:
  
  The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.
  
  Fig 23: Identifying Hole Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, disengage the 2 claws and remove the front door outside handle cover.
  
  Fig 24: Identifying Front Door Outside Handle Cover Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
1. Remove the hole plug.
2. Using a "TORX" socket wrench (T30), loosen the screw and remove the front door outside handle cover and the door lock key cylinder as a unit.
  HINT:
  
  The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.
  
  Fig 25: Identifying Front Door Outside Handle Cover & Door Lock Key Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System)
1. Remove the front door outside handle assembly as shown below.
  
  Fig 26: Identifying Front Door Outside Handle Assembly (Without Smart Key System)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System)
1. Disconnect the connector.
  
  Fig 27: Disconnecting Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the front door outside handle assembly as shown below.
  
  Fig 28: Identifying Front Door Outside Handle Assembly (With Smart Key System)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Disengage the 3 claws and remove the front door front outside handle pad.
  
  Fig 29: Identifying Front Door Front Outside Handle Pad Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Disengage the 2 claws and remove the front door rear outside handle pad.
  
  Fig 30: Identifying Front Door Rear Outside Handle Pad Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR LOCK ASSEMBLY
1. Using a "TORX" socket wrench (T30), remove the 3 screws.
2. Slide the front door lock assembly downward, and remove the front door lock assembly and cables as a unit.
3. Remove the door lock wiring harness seal from the front door lock assembly.
  
  Fig 31: Identifying Front Door Lock Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
1. Remove the front door lock remote control cable assembly.
  
  Fig 32: Identifying Front Door Lock Remote Control Cable Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY
1. Using a screwdriver, disengage the 3 claws.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 33: Identifying Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the front door inside locking cable assembly.
  
  Fig 34: Identifying Front Door Inside Locking Cable Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System)
1. Using a "TORX" socket wrench (T30), remove the screw.
2. Disengage the 2 claws and remove the front door outside handle frame sub-assembly.
  
  Fig 35: Identifying Front Door Outside Handle Frame Sub-Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System)
1. Using a "TORX" socket wrench (T30), remove the screw.
2. Disconnect the connector.
3. Disengage the clamp.
4. Disengage the 2 claws and remove the front door outside handle frame sub-assembly.
  
  Fig 36: Identifying Front Door Outside Handle Frame Sub-Assembly Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR LOCK OPEN ROD
1. Remove the front door lock open rod as shown below.
  
  Fig 37: Identifying Front Door Lock Open Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System)
1. Remove the screw and door electrical key oscillator.
  
  Fig 38: Identifying Door Electrical Key Oscillator Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR CHECK ASSEMBLY
1. Remove the bolt, 2 nuts, and front door check assembly.
  
  Fig 39: Identifying Front Door Check Assembly Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WEATHERSTRIP
1. Using a clip remover, disengage the 17 clips and remove the front door weatherstrip.
  
  Fig 40: Identifying Front Door Weatherstrip Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR FRAME GARNISH
1. Disengage the clip and remove the door frame garnish.
  HINT:
  
  This clip needs to be replaced with a new one because the clip will break when removing the door frame garnish.
  
  Fig 41: Identifying Door Frame Garnish Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR NO. 2 STIFFENER CUSHION
1. Remove the 2 bolts.
2. Remove the 2 guides and the front door No. 2 stiffener cushion.
  
  Fig 42: Identifying Front Door No. 2 Stiffener Cushion Guides & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR BELT MOLDING ASSEMBLY (See REMOVAL )
REMOVE FRONT DOOR WEATHERSTRIP
1. Disengage the claw.
2. Disengage the 8 clips and remove the front door weatherstrip.
  
  Fig 43: Identifying Front Door Weatherstrip Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE MOLDING SUB-ASSEMBLY (See REMOVAL )
REMOVE NO. 1 BLACK OUT TAPE (See REMOVAL )
REMOVE INNER UPPER BLACK OUT FRONT DOOR TAPE (See REMOVAL )
REMOVE INNER REAR BLACK OUT FRONT DOOR TAPE (See REMOVAL )