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Front Door: Disassembly

  1. DISCONNECT NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait for 90 seconds after disconnecting the terminal to prevent airbag deployment (See AIRBAG SYSTEM ).
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  2. 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 With Claw And Clip
    G05422096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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: Removing Front Door Inside Handle Bezel Plug
    G05422097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. 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: Removing Front Armrest Upper Base Panel
    G05422098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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 With Screws
    G05420257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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
    G05422100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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
    G05422101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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: Removing Assist Grip Cover
    G05422102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. 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: Removing Courtesy Light Assembly
    G05422103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 3 screws.
      Fig 9: Identifying Front Door Trim Board Sub-Assembly With Screws
      G05422104Courtesy 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 With Clips And Claws
      G05422105Courtesy 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: Disconnecting Front Door Lock Remote Control Cable And Front Door Inside Locking Cable
    G05422106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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 With Claws
    G05422107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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
    G05422108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Remove the front door inner glass weatherstrip from the front door panel.
  14. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY  (See INSTALLATION )
  15. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER  (See REMOVAL )
    Fig 14: Identifying Front Door Inner Glass Weatherstrip
    G05422109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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: Locating Front Door Service Hole Cover With Clamps
      G05422110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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 Power Window Regulator Master Switch Assembly And Front Door Glass Sub-Assembly
      G05422111Courtesy 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 Of Front Door Glass Sub-Assembly
      G05422112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the front door glass sub-assembly as shown in the illustration.
      NOTE: Do not damage the door glass.
      Fig 18: Removing Front Door Glass Sub-Assembly
      G05422113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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.
    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.
    Fig 19: Identifying Front Door Window Regulator Sub-Assembly Bolts And Temporary Bolt
    G05422114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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: Locating Front Power Window Regulator Motor Assembly Screws
    G05421172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
    Fig 21: Identifying Front Door Glass Run
    G06114058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the bolt and the front door rear lower frame sub-assembly as shown in the illustration.
    Fig 22: Removing Bolt And Front Door Rear Lower Frame Sub-Assembly
    G05422117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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: Loosening Front Door Outside Handle Cover Screw
      G05422118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, disengage the 2 claws and remove the front door outside handle cover.
    Fig 24: Removing Front Door Outside Handle Cover
    G05422119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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: Loosening Front Door Outside Handle Cover Screw
      G05422120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System) 
    1. Remove the front door outside handle assembly as shown in the illustration.
    Fig 26: Removing Front Door Outside Handle Assembly
    G05422121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System) 
    1. Disconnect the connector.
      Fig 27: Locating Front Door Outside Handle Connector
      G05420350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door outside handle assembly as shown in the illustration.
    Fig 28: Removing Front Door Outside Handle Assembly
    G05420351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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
    G05422124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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
    G05422125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 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: Removing Front Door Lock Assembly And Cables
    G05420276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. 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
    G05420277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. 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 Of Front Door Inside Locking Cable Assembly
      G05420278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door inside locking cable assembly.
    Fig 34: Identifying Front Door Inside Locking Cable Assembly
    G05420279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. 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: Disengaging Claws And Removing Front Door Outside Handle Frame Sub-Assembly
    G05422130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. 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: Removing Front Door Outside Handle Frame Sub-Assembly
    G05422131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DOOR LOCK OPEN ROD 
    1. Remove the front door lock open rod as shown in the illustration.
    Fig 37: Removing Front Door Lock Open Rod
    G05422132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System) 
    1. Remove the screw and door electrical key oscillator.
    Fig 38: Removing Screw And Door Electrical Key Oscillator
    G05422133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts, and front door check assembly.
    Fig 39: Identifying Front Door Check Assembly With Bolt And Nuts
    G05422134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. 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
    G05422135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. 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
      G05422136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. 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.
  39. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY  (See REMOVAL )
    Fig 42: Identifying Front Door No. 2 Stiffener Cushion With Guides And Bolts
    G05422137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Disengage the claw.
    2. Disengage the 8 clips and remove the front door weatherstrip.
  41. REMOVE FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY  (See REMOVAL )
  42. REMOVE NO. 1 BLACK OUT TAPE  (See REMOVAL )
  43. REMOVE INNER UPPER BLACK OUT FRONT DOOR TAPE  (See REMOVAL )
  44. REMOVE INNER REAR BLACK OUT FRONT DOOR TAPE  (See INSTALLATION )
Fig 43: Identifying Front Door Weatherstrip Clips And Claws
G05422138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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