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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (Hybrid) >> Front Door >> Disassembly [10/2014 - ] >> Procedure

Disassembly [10/2014 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work (Refer to PRECAUTION [10/2014 - ] ).

  2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 2

  3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL 
    WARNING:

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

  4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a moulding remover, disengage the 3 claws to remove the front door inside handle bezel plug.
      GTY377317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Disengage the claw and clip to remove the front door lower frame bracket garnish.
      GTY552742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) 
    1. Put protective tape around the front door trim board sub-assembly.
      GTY383813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape
    2. Using a moulding remover, disengage the clip, 9 claws and 2 guides.
    3. Using a screwdriver, disengage the 2 clips and guide.
      GTY377296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

    4. w/ illumination:
      1. Disengage the 2 clamps.
        GTY600602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect each connector to remove the multiplex network master switch assembly with front door armrest base panel.
  7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) 
    1. Put protective tape around the front door trim board sub-assembly.
      GTY376943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape
    2. Using a moulding remover, disengage the clip, 10 claws and 2 guides.
    3. Using a screwdriver, disengage the 2 clips and guide.
      GTY383817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape

      HINT: 

      Tape the screwdriver tip before use.

    4. w/ illumination:
      1. Disengage the 2 clamps.
        GTY552474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect each connector to remove the power window regulator switch assembly with front door armrest base panel.
  8. REMOVE NO. 1 FRONT DOOR STIFFENER CUSHION 
    1. Remove the screw and No. 1 front door stiffener cushion.
      GTY552741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Put protective tape around the front door panel.
      GTY377312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Protective Tape
    2. Remove the clip and 3 screws.
      GTY542688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Screw
      *2 Clip
    3. Using a clip remover, disengage the 9 clips.
      GTY552745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.
      GTY377314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect each connector to remove the front door trim board sub-assembly.
  11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the 2 claws and guide, and remove the front door inside handle sub-assembly.
      GTY552620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Disengage the 8 claws as shown in the illustration and remove the front door inner glass weatherstrip.
      GTY384247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE SEAT MEMORY SWITCH (w/ Memory) 

    Refer to PROCEDURE - Step 2

  14. REMOVE DOOR SIDE AIRBAG SENSOR 

    Refer to PROCEDURE - Step 11

  15. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 8

  16. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  17. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) 

    Refer to PROCEDURE - Step 7

  18. REMOVE FRONT DOOR TRIM BRACKET 
    1. Remove the screw and front door trim bracket.
      GTY552753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Remove the bolt.
      GTY552746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 connectors.
      GTY552752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage each clamp.
    4. Remove the front door service hole cover.
      GTY377323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Remove any remaining butyl tape from the front door panel.

  20. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the grommet.
      GTY552755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the cable to the negative (-) auxiliary battery terminal.
    3. Connect the multiplex network 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 (-) auxiliary battery terminal.
      WARNING:

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

    5. Disconnect the multiplex network master switch assembly.
    6. Remove the 2 bolts.
      GTY552757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After the bolts are removed, do not allow the front door glass sub-assembly to fall.

    7. Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.
      GTY371643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the front door glass sub-assembly.

  21. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Loosen the temporary bolt.
      GTY588115Courtesy 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.
  22. 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.
      GTY552762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 2 FRONT DOOR STIFFENER CUSHION 
    1. Remove the 2 bolts.
      GTY562842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Double-sided Tape
      *2 Guide
    2. Disengage the 2 guides and remove the No. 2 front door stiffener cushion.
  24. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
      GTY552760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      GTY552627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide to remove the front door rear lower frame sub-assembly.
  26. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
      GTY552630Courtesy 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.
      GTY552629Courtesy 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 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.
      GTY384255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Remove the hole plug.
      GTY600636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.
      GTY552631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  29. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. w/ Smart Key System:
      1. Disengage the 2 claws.
      2. Using a screwdriver, disconnect the connector.
        GTY377162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Move the lever in the direction indicated by the arrow in the illustration.
      GTY377160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the front door outside handle assembly as shown in the illustration.
      GTY377161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws to remove the front door front outside handle pad.
      GTY552634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws to remove the front door rear outside handle pad.
      GTY552633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the 3 screws.
      GTY586886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front Door Lock Open Rod
    2. Slide the front door lock with motor assembly downward to 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.
        GTY552639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 6 claws.
      GTY377200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door inside locking cable assembly.
      GTY377198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Remove the front door lock remote control cable assembly.
      GTY377212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. w/ Smart Key System:
      1. Disconnect the connector.
        GTY552471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disengage the 3 clamps.
    2. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY540269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.
  36. REMOVE FRONT SMART DOOR WIRE (w/ Smart Key System) 
    1. Disengage the 3 clamps to remove the front smart door wire.
      GTY552473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. 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.
      GTY570436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the bolt and 2 nuts, and front door check assembly.
      GTY591354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Nut
  39. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 18 clips and remove the front door weatherstrip.
      GTY552618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE DOOR FRAME GARNISH 
    1. Disengage the 3 claws to remove the door frame garnish.
      GTY600633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Using a clip remover, disengage the 9 clips and remove the front door No. 2 weatherstrip.
      GTY552622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 15

  43. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 5

  44. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 6

  45. REMOVE NO. 1 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 19

  46. REMOVE NO. 2 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 20

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