Front Door: Disassembly: Disassembly

HINT: 

• Use the same procedure for both the RH and LH sides.
• The procedure described below is for the LH side.

1. PRECAUTION 
   NOTE:

   After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION .

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
   WARNING:

   Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

   NOTE:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
   1. Using a moulding remover, disengage the 3 claws and remove the front door inside handle bezel plug as shown in the illustration.
      Fig 1: Identifying Front Door Inside Handle Bezel Plug Claws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
   1. Disengage the 3 clips and remove the front door lower frame bracket garnish.
      Fig 2: Identifying Front Door Lower Frame Bracket Garnish Clips

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) 
   1. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.
      Fig 3: Identifying Power Window Regulator Master Switch Clips, Claws And Guides (For Driver Side)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Disconnect each connector and remove the power window regulator master switch assembly with front door armrest base panel.
6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) 
   1. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.
      Fig 4: Identifying Power Window Regulator Switch Clips, Claws And Guides (For Front Passenger Side)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Disconnect each connector and remove the power window regulator switch assembly with front door armrest base panel.
7. REMOVE FRONT ARMREST ASSEMBLY 
   1. Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the front armrest assembly.
      Fig 5: Identifying Front Armrest Assembly Clips, Claws And Guides

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE COURTESY LIGHT ASSEMBLY  . Refer to REMOVAL - Step 1 .
9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
   1. Put protective tape around the front door panel.
      Fig 6: Identifying Protective Tape Placement

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	Protective Tape

   2. Remove the 3 screws.
      Fig 7: Identifying Front Door Trim Board Screws And Clips

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a clip remover, disengage the 10 clips.
   4. Pull out the front door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.
      Fig 8: Pulling Out Front Door Trim Board Sub-Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	Reference Boss
      *2	Front Door Inner Glass Weatherstrip

   5. Disengage the reference boss from the front door panel.
   6. Raise the front door trim board sub-assembly to remove the front door trim board sub-assembly together with the front door inner glass weatherstrip.
   7. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.
      Fig 9: Disconnecting Front Door Lock Remote Control And Inside Locking Cables

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the 2 claws and guides, and remove the front door inside handle sub-assembly.
       Fig 10: Identifying Front Door Inside Handle Sub-Assembly Claws And Guides

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Using a screwdriver, disengage the 4 claws and remove the front door inner glass weatherstrip from the front door trim board sub-assembly as shown in the illustration.
       Fig 11: Identifying Front Door Inner Glass Weatherstrip Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	Screwdriver

12. REMOVE DOOR SIDE AIRBAG SENSOR  . Refer to REMOVAL - Step 10 .
13. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY  . Refer to REMOVAL - Step 9 .
14. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY  . Refer to REMOVAL - Step 9 .
15. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Remove the bolt.
       Fig 12: Locating Front Door Service Hole Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect each connector.
    3. Disengage the 5 clamps.
    4. Remove the front door service hole cover.

       HINT: 

       Remove any remaining butyl tape from the door.

16. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the grommet.
       Fig 13: Identifying Front Door Grommet

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the cable to the negative (-) battery terminal.
    3. 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.
    4. Disconnect the cable from the negative (-) battery terminal.
       WARNING:

       Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

       NOTE:

       When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

    5. Disconnect the power window regulator master switch assembly.
    6. Remove the 2 bolts.
       Fig 14: Identifying Front Door Glass Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       After the bolts are removed, do not allow the door glass to fall.

    7. Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.
       Fig 15: Removing The Front Door Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       Do not damage the door glass.

17. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Loosen the temporary bolt.
       Fig 16: Identifying Front Door Window Regulator Temporary Bolt And Assembly Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	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 assembly.
    4. Remove the temporary bolt from the front door window regulator assembly.
18. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    1. Using a T25 "TORX" socket wrench, remove the 3 screws and front power window regulator motor assembly.
       Fig 17: Identifying Front Power Window Regulator Motor Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE NO. 2 FRONT DOOR STIFFENER CUSHION 
    1. Remove the 2 bolts.
       Fig 18: Identifying No. 2 Front Door Stiffener Cushion Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	Double-sided Tape

    2. Disengage the 2 guides and remove the No. 2 front door stiffener cushion.
20. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
       Fig 19: Identifying Front Door Glass Run

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts.
       Fig 20: Identifying Front Door Front Lower Frame Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and remove the front door front lower frame sub-assembly as shown in the illustration.
22. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts.
       Fig 21: Identifying Front Door Rear Lower Frame Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration.
23. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
       Fig 22: Identifying Front Door Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover with lock cylinder assembly.
       Fig 23: Identifying Front Door Outside Handle Cover w/ Lock Cylinder

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT: 

       The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

24. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Front Passenger Side) 
    1. w/ Front Door Lock Cylinder:

       HINT: 

       Use the same procedure for front passenger side and driver side.

25. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) 
    1. Using a screwdriver, disengage the claw and 2 guides, and remove the front door outside handle cover as shown in the illustration.
       Fig 24: Removing Front Door Outside Handle Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. w/ Front Door Lock Cylinder:

       HINT: 

       Use the same procedure for the front passenger side and the driver side.

    2. w/o Front Door Lock Cylinder:
       1. Remove the hole plug.
          Fig 25: Identifying Front Door Hole Plug

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.
          Fig 26: Identifying Front Door Outside Handle Cover w/o Front Door Lock Cylinder

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          HINT: 

          The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. w/ Smart Key System:
       1. Disengage the 2 claws.
       2. Using a screwdriver, disconnect the connector.
          Fig 27: Identifying Front Door Outside Handle Connector

          Courtesy 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

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. 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
29. 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
30. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the 3 screws.
       Fig 31: Identifying Front Door Lock With Motor Assembly Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	Front Door Lock Open Rod

    2. Slide the front door lock with motor assembly downward, and remove the front door lock with motor assembly and cables as a unit.
    3. When reusing the front door lock with motor assembly:
       1. Remove the door lock wiring harness seal from the front door lock with motor assembly.
          Fig 32: Identifying Door Lock Wiring Harness Seal

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Remove the front door lock remote control cable assembly.
       Fig 33: Removing Front Door Lock Remote Control Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 3 claws.
       Fig 34: Identifying Front Door Inside Locking Cable Claws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door inside locking cable assembly.
       Fig 35: Removing Front Door Inside Locking Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. w/ Smart Key System:
       1. Disconnect the connector.
          Fig 36: Identifying Connector And Clamps

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       2. Disengage the 3 clamps.
    2. Using a T30 "TORX" socket wrench, remove the screw and door handle nut.
       Fig 37: Identifying Front Door Outside Handle Frame Screw And Door Handle Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       TEXT IN ILLUSTRATION
       
       

       *1	Door Handle Nut
       *a	Outside
       *b	Inside

    3. Slide the front door outside handle frame sub-assembly to disengage the claw of the front door outside handle frame sub-assembly, and then remove it.
34. REMOVE FRONT DOOR WIRE (w/ Smart Key System) 
    1. Disengage the 3 clamps and remove the front door wire.
       Fig 38: Identifying Front Door Wire Clamps

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. REMOVE FRONT DOOR LOCK OPEN ROD 
    1. Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.
       Fig 39: Removing Front Door Lock Open Rod

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the 3 bolts and front door check assembly.
       Fig 40: Identifying Front Door Check Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
37. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.
       Fig 41: Identifying Front Door Weatherstrip Clips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. REMOVE DOOR FRAME GARNISH 
    1. Disengage the clip and remove the door frame garnish.
       Fig 42: Identifying Door Frame Garnish Clip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT: 

       This garnish needs to be replaced with a new one because the clip will break when removing it.

39. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Using a clip remover, disengage the 8 clips and remove the front door No. 2 weatherstrip.
       Fig 43: Identifying Front Door No. 2 Weatherstrip Clips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
40. REMOVE FRONT DOOR PANEL CUSHION 
    1. Disengage the 2 claws and remove the 2 front door panel cushions.
       Fig 44: Identifying Front Door Panel Cushions

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. REMOVE DOOR DUST PROOF SEAL 
    1. Remove the door dust proof seal.
       Fig 45: Identifying Door Dust Proof Seal

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY  . Refer to REMOVAL - Step 7 .
43. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING  . Refer to REMOVAL - Step 11 .
44. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING  . Refer to REMOVAL - Step 12 .
45. REMOVE FRONT DOOR STRIPE  . Refer to REMOVAL - Step 11 .
46. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE  . Refer to REMOVAL - Step 12 .