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Home >> Toyota >> 2020 >> Mirai >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Doors / Hatch) - Service Information >> Front Door >> Disassembly [06/2015 - 11/2018] >> Procedure

Disassembly [06/2015 - 11/2018]: 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 notice before proceeding with work.

    Refer to PRECAUTION [06/2015 - ]

  2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 2

  3. 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.

    GTY581108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a moulding remover A, disengage the claws to remove the front door inside handle bezel plug as shown in the illustration.
      GTY577310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  5. REMOVE FRONT DOOR ARMREST COVER 
    1. Using a moulding remover A, disengage the claw and guides to remove the front door armrest cover.
      GTY607850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  6. REMOVE NO. 1 FRONT DOOR STIFFENER CUSHION 
    1. Remove the No. 1 front door stiffener cushion with the screw.
      GTY610190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 3 screws.
      GTY595219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clips as shown in the illustration.
      GTY575247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hands Here
      Remove in this Direction
    3. Disengage the clamps to separate the front door trim board sub-assembly as shown in the illustration.
      GTY582744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hands Here
      Remove in this Direction
    4. Disconnect the connector.
      GTY595236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disengage the guides.
      GTY595542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
    6. Disconnect the front door inside locking cable assembly and front door lock remote control cable assembly to remove the front door trim board sub-assembly.
  9. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the claws to remove the front door inside handle sub-assembly from the front door trim board sub-assembly.
      GTY542340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      Remove in this Direction
  10. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side) 

    Refer to PROCEDURE - Step 6

  11. REMOVE OUTER MIRROR SWITCH ASSEMBLY (for Driver Side) 

    Refer to PROCEDURE - Step 6

  12. REMOVE SEAT MEMORY SWITCH (for Driver Side) 

    Refer to PROCEDURE - Step 2

  13. REMOVE DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) 

    Refer to PROCEDURE - Step 7

  14. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) 

    Refer to PROCEDURE - Step 6

  15. REMOVE FRONT DOOR WIRE 
    1. Using a clip remover, disengage the clamps to remove the front door wire from the front door trim board sub-assembly.
      GTY595240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DOOR GLASS INNER WEATHERSTRIP 
    1. Remove the front door glass inner weatherstrip as shown in the illustration.
      GTY580768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  17. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  18. REMOVE DOOR SIDE AIR BAG SENSOR 

    Refer to PROCEDURE - Step 5

  19. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY 

    Refer to PROCEDURE - Step 6

  20. REMOVE OUTER MIRROR INSTALL HOLE COVER 

    Refer to PROCEDURE - Step 6

  21. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  22. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Remove the front door service hole cover.
      GTY555142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Butyl Tape
      NOTE:

      Remove any remaining butyl tape from the front door panel.

  23. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Connect the multiplex network master switch assembly.
    2. Connect the cable to the auxiliary battery negative (-) terminal.
    3. Move the front door glass sub-assembly so that the door glass bolts can be seen.
    4. Disconnect the cable from the auxiliary battery negative (-) terminal.
      WARNING:
      GTY581108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Wait at least 90 seconds after disconnecting the cable from the auxiliary battery negative (-) terminal to disable the SRS system.
      • If the airbag deploys for any reason, it may cause a serious accident.
      NOTE:

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

      Refer to INITIALIZATION [06/2015 - 11/2018]

    5. Disconnect the multiplex network master switch assembly.
    6. Remove the 2 bolts.
      GTY595234Courtesy 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 shown in the illustration.
      GTY592000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
      NOTE:

      Do not damage the front door glass sub-assembly.

  24. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Disconnect the connector.
      GTY539403Courtesy 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 sub-assembly may fall and cause damage.

    3. Remove the 5 bolts and front door window regulator sub-assembly.
    4. Remove the temporary bolt from the front door window regulator sub-assembly.
  25. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run as shown in the illustration.
      GTY598984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  26. REMOVE DOOR FRAME GARNISH 
    1. Disengage the guides to remove the door frame garnish as shown in the illustration.
      GTY602321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  27. REMOVE NO. 1 FRONT DOOR STIFFENER CUSHION 
    1. Remove the 2 bolts.
      GTY566825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-side Tape
    2. Remove the double-side tape and No. 1 front door stiffener cushion.
      NOTE:

      Remove any remaining double-side tape from the front door panel.

  28. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the bolt.
      GTY610184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide to remove the front door rear lower frame sub-assembly.
  29. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Raise up the front door weatherstrip and then remove the screw.
    2. Remove the 3 bolts, screw and front door front lower frame sub-assembly.
      GTY595193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT DOOR FIX WINDOW GLASS 
    1. Remove the front door fix window glass as shown in the illustration.
      GTY608549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  31. REMOVE FRONT DOOR FIX WINDOW WEATHERSTRIP 
    1. Remove the front door fix window weatherstrip from the front door fix window glass.
      GTY595196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
      GTY610182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY563544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Remove the front door lock cylinder assembly as shown in the illustration.
  33. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH (for Driver Side) 
    1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and guides to remove the front door outside handle cover LH.
      GTY570779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
  34. REMOVE FRONT DOOR OUTSIDE HANDLE COVER RH (for Front Passenger Side) 
    1. Remove the hole plug.
      GTY595189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY607856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Disengage the claws to remove the front door outside handle cover RH as shown in the illustration.
  35. REMOVE FRONT DOOR WITH MOTOR LOCK ASSEMBLY 

    Refer to PROCEDURE - Step 15

  36. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Using a screwdriver with its tip wrapped in protective tape, disengage the claws to open the cover as shown in the illustration.
      GTY590908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      Remove in this Direction
    2. Using a screwdriver with its tip wrapped in protective tape, disconnect the connector.
      GTY598884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
    3. Remove the front door outside handle assembly as shown in the illustration.
      GTY551388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  37. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the claws to remove the front door front outside handle pad.
      GTY558689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  38. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the claws to remove the front door rear outside handle pad.
      GTY565451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  39. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a clip remover, disengage the clamps and guide to separate the wire harness.
      GTY595562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Guide
    2. GTY542436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      *b Guide
      Remove in this Direction

      Using a T30 "TORX" socket wrench, loosen the screw.

    3. Disengage the grommet and guides to remove the front door outside handle frame sub-assembly as shown in the illustration.
  40. REMOVE FRONT DOOR LOCK OPEN ROD 
    1. Disconnect the snap to remove the front door lock open rod from the front door outside frame sub-assembly as shown in the illustration.
      GTY548569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Snap
  41. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the bolt, 2 nuts and front door check assembly.
      GTY595209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 3 FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, remove the 4 clips and No. 3 front door weatherstrip.
      GTY595208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 2 FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the clips to remove the No. 2 front door weatherstrip.
      GTY595207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, remove the 2 clips.
      GTY569326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-side Tape
    2. Using a clip remover, disengage the clips.
    3. Remove the double-side tape and front door weatherstrip.
      NOTE:

      Remove any remaining double-side tape from the front door panel.

  45. REMOVE FRONT DOOR PANEL CUSHION 
    1. Disengage the claw to remove the front door panel cushion.
      GTY595071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE HOLE PLUG 
    1. Remove the 3 hole plugs.
      GTY595069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 12

  48. REMOVE FRONT DOOR WINDOW FRAME REAR MOULDING 

    Refer to PROCEDURE - Step 5

  49. REMOVE FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  50. REMOVE FRONT DOOR OUTSIDE STRIPE 

    Refer to PROCEDURE - Step 7

  51. REMOVE FRONT DOOR REAR OUTSIDE STRIPE 

    Refer to PROCEDURE - Step 8

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