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Front Door: Disassembly: Disassembly

  1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Disengage the 2 clips and remove the front door lower frame bracket garnish.
      Fig 1: Identifying Front Door Lower Frame Bracket Garnish Clips
      GTY196575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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
      GTY196576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ASSIST GRIP COVER 
    1. Using a screwdriver with the tip wrapped with protective tape, disengage the 6 claws and remove the assist grip cover.
      Fig 3: Identifying Assist Grip Cover Claws
      GTY172204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE COURTESY LIGHT ASSEMBLY 
    1. Using a screwdriver with the tip wrapped with protective tape, disengage the claw and remove the courtesy light assembly.
      Fig 4: Identifying Courtesy Light Assembly
      GTY177300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector.
  5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 3 screws and clip (A).
      Fig 5: Identifying Front Door Trim Board Sub-Assembly Screws And Clip
      GTY196579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a clip remover, disengage the 9 clips.
    3. Pull up the front door trim board in the direction indicated by the arrow.
      Fig 6: Identifying Front Door Trim Board Claws
      GTY197012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the reference bosses from the front door panel.
    5. Raise the front door trim board to disengage the 4 claws and remove the front door trim board together with the front door inner glass weatherstrip.
    6. Disengage the 2 claws and disconnect the front door inside handle sub-assembly.
      Fig 7: Identifying Front Door Inside Handle Sub-Assembly Claws
      GTY180336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY 
    1. Disconnect the connector.
      Fig 8: Identifying Power Window Regulator Master Switch Assembly Screws
      GTY197013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 screws and the power window regulator master switch assembly.
  7. REMOVE FRONT DOOR WIRE (for Driver Side) 
    1. Disengage the clamp and remove the 2 screws and front door wire.
      Fig 9: Locating Front Door Wire Screws And Clamp
      GTY177938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Using a screwdriver, disengage the 4 clips as shown in the illustration and remove the front door inner glass weatherstrip from the front door trim board.
      Fig 10: Identifying Front Door Inner Glass Weatherstrip Clips
      GTY187489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT ARMREST BASE PANEL UPPER 
    1. Remove the 7 screws.
      Fig 11: Locating Front Armrest Base Panel Upper Claws And Screws
      GTY197014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 4 claws and remove the front armrest base panel upper.
  10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disconnect the front door lock remote control cable and front door inside locking cable and remove the front door inside handle sub-assembly.
      Fig 12: Disconnecting Front Door Lock Remote Control Cable And Front Door Inside Locking Cable
      GTY197015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY  . Refer to REMOVAL - Step 7
  12. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY  . Refer to REMOVAL - Step 2
  13. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Disconnect the connector and each clamp, and remove the front door service hole cover.
      Fig 13: Identifying Connector, Clamp And Front Door Service Hole Cover
      GTY197602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Remove the remaining butyl tape on the door side.

  14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Connect the front power window regulator motor assembly connector.
    2. 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.
    3. Remove the 2 bolts.
      Fig 14: Identifying Door Glass Bolts
      GTY197017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After the bolts are removed, the door glass may fall, causing damage.

    4. Remove the front door glass sub-assembly as shown in the illustration.
      Fig 15: Removing Front Door Glass Sub-Assembly
      GTY197018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the door glass.

    5. Disconnect the power window regulator master switch assembly and front power window regulator motor assembly connector.
  15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Loosen the temporary bolt.
      Fig 16: Identifying Temporary Bolt
      GTY197020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall, causing damage.

    2. Remove the 5 bolts.
    3. Remove the front door window regulator sub-assembly and the power window regulator motor assembly front as a unit.
    4. Remove the temporary bolt from the front door window regulator sub-assembly.
  16. 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 17: Locating Front Power Window Regulator Motor Screws
      GTY171683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT NO. 1 DOOR STIFFENER CUSHION 
    1. Disengage the 2 claws.
      Fig 18: Identifying Front No. 1 Door Stiffener Cushion Double-Sided Tape
      GTY197023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the double-sided tape and the front No. 1 door stiffener cushion.
  18. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
      Fig 19: Identifying Front Door Glass Run
      GTY185320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE DOOR FRAME GARNISH 
    1. Disengage the clip and remove the door frame garnish.
      Fig 20: Identifying Door Frame Garnish Clip
      GTY186805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts and the front door front lower frame sub-assembly as shown in the illustration.
      Fig 21: Identifying Front Door Front Lower Frame Sub-Assembly Bolts
      GTY197025Courtesy 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: Identifying Front Door Rear Lower Frame Sub-Assembly Bolt
      GTY197026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER 
    1. Remove the hole plug.
      Fig 23: Identifying Front Door Lock Cylinder Screw
      GTY197027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

    3. Using a screwdriver, disengage the 2 claws and remove the front door outside handle cover.
      Fig 24: Disengaging Front Door Outside Handle Cover Claws
      GTY197030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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 25: Identifying Front Door Outside Handle Assembly
      GTY197138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System) 
    1. Disconnect the connector.
      Fig 26: Locating Connector
      GTY173589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door outside handle assembly as shown in the illustration.
      Fig 27: Removing Front Door Outside Handle Assembly
      GTY197028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws and remove the front door front outside handle pad.
      Fig 28: Identifying Front Door Front Outside Handle Pad Claws
      GTY197032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws and remove the front door rear outside handle pad.
      Fig 29: Identifying Front Door Rear Outside Handle Pad Claws
      GTY169759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT DOOR LOCK ASSEMBLY 
    1. Disconnect the connector.
      Fig 30: Identifying Front Door Lock Assembly Screws
      GTY197033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a "TORX" socket wrench (T30), remove the 3 screws.
    3. Slide the front door lock assembly downward, pull out the front door lock open rod from the outside handle frame, and remove the front door lock assembly and cables as a unit.
    4. Remove the front door lock open rod from the front door lock assembly.
    5. Remove the door lock wiring harness seal from the front door lock assembly.
  28. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Remove the front door lock remote control cable assembly.
      Fig 31: Identifying Front Door Lock Remote Control Cable Assembly
      GTY168490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 3 claws.
      Fig 32: Identifying Front Door Inside Locking Cable Assembly Claws
      GTY168351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Tape the screwdriver tip before use.

    2. Remove the front door inside locking cable assembly.
      Fig 33: Identifying Front Door Inside Locking Cable Assembly
      GTY197034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System) 
    1. Using a "TORX" socket wrench (T30), remove the screw.
      Fig 34: Identifying Front Door Outside Handle Frame Sub-Assembly Claw And Screw
      GTY197035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw and remove the front door outside handle frame sub-assembly.
  31. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System) 
    1. Using a "TORX" socket wrench (T30), remove the screw.
      Fig 35: Identifying Front Door Outside Handle Frame Sub-Assembly
      GTY197137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector.
    3. Disengage the 2 clamps.
    4. Disengage the claws and remove the front door outside handle frame sub-assembly.
  32. REMOVE DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System) 
    1. Remove the screw and door electrical key oscillator.
      Fig 36: Locating Door Electrical Key Oscillator Screw
      GTY197145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DOOR CHECK ASSEMBLY (for TMC Made) 
    1. Remove the 3 bolts and the front door check assembly.
      Fig 37: Identifying Front Door Check Assembly Bolts
      GTY187497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT DOOR CHECK ASSEMBLY (for TMMK Made) 
    1. Remove the bolt, 2 nuts, and the front door check assembly.
      Fig 38: Identifying Front Door Check Assembly Bolt And Nuts
      GTY182572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.
      Fig 39: Identifying Front Door Weatherstrip Clips
      GTY169152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR BELT MOLDING ASSEMBLY  . Refer to REMOVAL - Step 8
  37. REMOVE FRONT DOOR REAR WINDOW FRAME MOLDING  . Refer to REMOVAL - Step 14
  38. REMOVE FRONT DOOR UPPER WINDOW FRAME MOLDING  . Refer to REMOVAL - Step 15
  39. REMOVE FRONT DOOR STRIPE  . Refer to REMOVAL - Step 15
  40. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE  . Refer to REMOVAL - Step 16
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