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Home >> Toyota >> 2016 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 122 ((Door / Hatch) (Service Information) (Hybrid) (2 Of 2)) >> Front Door >> Disassembly [02/2014 - 11/2015] >> Procedure

Disassembly [02/2014 - 11/2015]: Procedure

WARNING: This page is about a different variant/trim than selected.
  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 [02/2014 - 11/2016]

  2. REMOVE DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 1

  3. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. DISCONNECT CABLE FROM 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.

    NOTE:

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

    Refer to INITIALIZATION [02/2014 - 11/2016]

  5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Disengage the 2 clips and guide and remove the front door lower frame bracket garnish.
      GTY429986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 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.
      GTY429980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. Using a moulding remover, disengage the 2 clips, 4 claws and 2 guides.
      GTY451744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect each connector and remove the power window regulator master switch assembly with front door upper armrest base panel.
  8. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side) 
    1. Using a moulding remover, disengage the 2 clips, 4 claws and 2 guides.
      GTY429982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect each connector and remove the power window regulator switch assembly with front door upper armrest base panel.
  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.
      GTY426174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a screwdriver with its tip wrapped with protective tape, disengage the claw and open the cover.
      GTY451227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Remove the 3 screws.
      GTY429973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 10 clips and remove the front door trim board sub-assembly as shown in the illustration.
      GTY429974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. w/ Memory:
      1. Disconnect the connector.
    6. w/ Illumination:
      1. Disconnect the connector.
    7. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.
      GTY451742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the 2 claws and guide, and remove the front door inside handle sub-assembly.
      GTY429978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Disengage the 7 claws and remove the front door inner glass weatherstrip as shown in the illustration.
      GTY429979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE SEAT MEMORY SWITCH (w/ Memory) 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 7

  15. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER 

    Refer to PROCEDURE - Step 7

  16. REMOVE DOOR SIDE AIR BAG SENSOR 

    Refer to PROCEDURE - Step 11

  17. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 7

  18. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Remove the front door service hole cover.
      GTY429961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Remove any remaining butyl tape from the front door panel.

  19. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the grommet.
      GTY429966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the cable to the negative (-) auxiliary battery terminal.
    3. for Driver Side:
      1. 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.
      2. Disconnect the power window regulator master switch assembly.
    4. for Front Passenger Side:
      1. Connect the power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
      2. Disconnect the power window regulator switch assembly.
    5. Disconnect the cable from the negative (-) auxiliary battery terminal.
    6. Remove the 2 bolts.
      GTY429967Courtesy 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.
      GTY454475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not damage the front door glass sub-assembly.

  20. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Disconnect the connector.
      GTY438377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporary Bolt
    2. Loosen the temporary bolt.
      NOTE:

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

    3. Remove the 5 bolts.
    4. Remove the front door window regulator assembly.
    5. Remove the temporary bolt from the front door window regulator assembly.
  21. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    1. Using a T25 "TORX" socket wrench, remove the 3 screws and power window regulator motor assembly.
      GTY430010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
      GTY430009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts and disconnect wire harness.
      GTY430007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts.
      GTY451750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the guide and remove the front door front lower frame sub-assembly.
  24. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the bolt.
      GTY430008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide and remove the front door rear lower frame sub-assembly.
  25. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
      GTY430006Courtesy 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.
      GTY451749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  26. 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.
      GTY430004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Remove the hole plug.
      GTY430005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.
      GTY429905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  28. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Disengage the 2 claws.
      GTY429906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disconnect the connector.
    3. Remove the front door outside handle assembly as shown in the illustration.
      GTY429912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws and remove the front door front outside handle pad.
      GTY429914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws and remove the front door rear outside handle pad.
      GTY429913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY 
    1. Disconnect the connector.
      GTY441510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Lock Open Rod
    2. Using a T30 "TORX" socket wrench, remove the 3 screws.
    3. Slide the front door lock with motor assembly downward to disconnect the front door lock open rod and remove the front door lock with motor assembly and cables as a unit.
    4. 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.
        GTY429922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Using a screwdriver, disengage the 2 claws as shown in the illustration.
      GTY429916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door lock remote control cable assembly as shown in the illustration.
      GTY451729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Remove the front door inside locking cable assembly as shown in the illustration.
      GTY429918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Disengage the 3 clamps.
      GTY429921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY427974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Inside
      *B Outside
    3. Slide the front door outside handle frame sub-assembly to disengage the claw, and then remove it.
  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.
      GTY440379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts and front door check assembly.
      GTY439289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  37. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 20 clips and remove the front door weatherstrip.
      GTY424414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FRONT DOOR NO. 2 STIFFENER CUSHION 
    1. Remove the 2 bolts.
      GTY452069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
    2. Disengage the 2 guides and remove the front door No. 2 stiffener cushion.
  39. REMOVE DOOR FRAME GARNISH 
    1. Disengage the 3 claws and remove the door frame garnish.
      GTY450534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE FRONT DOOR PANEL CUSHION 
    1. Disengage the 2 claws and remove the 2 front door panel cushions.
      GTY424413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE FRONT DOOR PANEL PROTECTOR 
    1. Remove the front door panel protector.
      GTY424411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT DOOR VENT SEAL 
    1. Remove the front door vent seal.
      GTY445242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  43. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 4

  44. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 3

  45. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 4

  46. REMOVE FRONT DOOR UPPER INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 16

  47. REMOVE FRONT DOOR REAR INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 17

  48. REMOVE FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  49. REMOVE FRONT DOOR UPPER OUTSIDE MOULDING PAD 

    Refer to PROCEDURE - Step 2

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