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Home >> Toyota >> 2021 >> Avalon Touring >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (1 Of 2) >> Front Door >> Disassembly [04/2018 - 08/2020] >> Procedure

Disassembly [04/2018 - 08/2020]: Procedure

  1. PRECAUTION 
    WARNING:

    Be sure to read Precaution thoroughly before servicing.

    GTY571595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    for Gasoline Model:

    Refer to PRECAUTION [04/2018 - 08/2020]

    for HV Model:

    Refer to PRECAUTION [04/2018 -]

    NOTE:

    After turning the engine switch (for Gasoline Model) or power switch (for HV Model) 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 [04/2018 -]

  2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER (for HV Model) 

    Refer to PROCEDURE - Step 2 [04/2018 - 08/2019] , or refer to PROCEDURE - Step 2 [08/2019 - 08/2021]

  3. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    for A25A-FXS:

    Refer to PROCEDURE - Step 3 [04/2018 - 08/2019] , or refer to PROCEDURE - Step 3 [08/2019 - 08/2021]

    for 2GR-FKS:

    Refer to PROCEDURE - Step 2

    WARNING:
    • Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.
    • If an airbag deploys for any reason, it may cause a serious injury.
    GTY684647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT DOOR ARMREST COVER SUB-ASSEMBLY 
    1. Using a moulding remover, disengage the 3 claws to remove the front door armrest cover sub-assembly.
      GTY868346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DOOR TRIM POCKET COVER 
    1. Disengage the claw and 2 guides to remove the front door trim pocket cover.
      GTY868351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. Apply protective tape to the front door trim board sub-assembly as shown in the illustration.
      GTY916324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a moulding remover, disengage the 3 clips and 3 claws as shown in the illustration.
      GTY920739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Disconnect the connector to remove the multiplex network master switch assembly with front door upper armrest base panel.
  7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side) 
    1. Apply protective tape to the front door trim board sub-assembly as shown in the illustration.
      GTY861159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a moulding remover, disengage the 3 claws as shown in the illustration.
      GTY869297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Disconnect the connector to remove the power window regulator switch assembly with front door upper armrest base panel.
  8. REMOVE COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Remove the 3 screws.
      GTY868355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 10 clips as shown in the illustration.
      GTY938503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction
    3. Disengage the 6 claws and guide as shown in the illustration.
      GTY900092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    4. Disconnect the front door lock open lever remote control cable and front door inside lock/unlock knob locking cable as shown in the illustration.
      GTY840483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Lock/Unlock Knob Locking Cable
      *2 Front Door Lock Open Lever Remote Control Cable
      Remove in this Direction
    5. w/ Seat Memory Switch:
      GTY850802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/ Seat Memory Switch
      *B w/ Illumination
      1. Disconnect the connector.
    6. w/ Illumination:
      1. Disconnect the connector.
    7. Remove the front door trim board sub-assembly.
  10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Disengage the 3 claws to remove the front door inside handle sub-assembly.
      GTY868366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE SEAT MEMORY SWITCH (w/ Seat Memory Switch) 

    Refer to PROCEDURE - Step 2

  12. REMOVE FRONT DOOR INSIDE PANEL PLATE (w/ Seat Memory Switch) 
    1. Disengage the 2 claws and remove the front door inside panel plate as shown in the illustration.
      GTY912521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  13. REMOVE FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY (w/ Illumination) 

    Refer to PROCEDURE - Step 7

  14. REMOVE FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY 
    1. Remove the 8 screws.
      GTY867638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door trim ornament sub-assembly as shown in the illustration.
      GTY840433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  15. REMOVE FRONT DOOR TRIM BODY BRACKET 
    1. Remove the 3 screws and front door trim body bracket.
      GTY867637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DOOR TRIM COVER 
    1. Remove the 10 screws.
      GTY867641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 guides to remove the front armrest assembly with front door trim cover as shown in the illustration.
      GTY859273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Disengage the 3 guides to remove the front door trim cover as shown in the illustration.
      GTY885422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  17. REMOVE FRONT DOOR PULL HANDLE 
    1. Remove the 2 screws.
      GTY938902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Disengage the 4 claws and guide to remove the front door pull handle as shown in the illustration.
  18. REMOVE FRONT DOOR ORNAMENT 
    1. Disengage the 2 guides to remove the front door ornament as shown in the illustration.
      GTY905536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  19. REMOVE PLUG PLATE (w/o Memory) 
    1. Remove the 2 plug plates.
      GTY868378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) 

    Refer to PROCEDURE - Step 7

  21. REMOVE HOLE PLUG 
    1. Remove the 2 hole plugs.
      GTY868379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Disengage the clip and guide to remove the front door lower frame bracket garnish.
      GTY932827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE HOLE PLUG 

    Refer to PROCEDURE - Step 7

  24. REMOVE OUTER MIRROR INSTALL HOLE COVER 

    Refer to PROCEDURE - Step 8

  25. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER 

    Refer to PROCEDURE - Step 9

  26. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 7

  27. REMOVE SIDE AIRBAG PRESSURE SENSOR 

    Refer to PROCEDURE - Step 12

  28. REMOVE FRONT DOOR TRIM BRACKET 
    1. Remove the screw and front door trim bracket.
      GTY868376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Disengage the 2 clamps.
      GTY868373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn each front door weatherstrip clip 45 degrees as shown in the illustration and remove the 4 front door weatherstrip clips.
      GTY868375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 3 clips to remove the front door service hole cover.
      GTY868323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Disengage the 2 guides and remove the front door inner glass weatherstrip as shown in the illustration.
      GTY890192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  31. REMOVE FRONT DOOR PANEL PROTECTOR 
    1. Remove the front door panel protector as shown in the illustration.
      GTY900117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  32. REMOVE FRONT DOOR VENT SEAL 
    1. Disengage the clip and disconnect the front door weatherstrip as shown in the illustration.
      GTY868326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door vent seal as shown in the illustration.
      GTY920962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  33. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the hole plug.
      GTY868320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Driver Side:
      1. Connect the multiplex network master switch assembly.
    3. for Front Passenger Side:
      1. Connect the power window regulator switch assembly.
    4. for Gasoline Model:
      1. Connect the cable to the negative (-) battery terminal.
    5. for HV Model:
      1. Connect the cable to the negative (-) auxiliary battery terminal.
    6. for Gasoline Model:
      1. Turn the engine switch on (IG).
    7. for HV Model:
      1. Turn the power switch on (IG).
    8. Move the front door glass sub-assembly so that the door glass bolts can be seen.
    9. for Gasoline Model:
      1. Turn the engine switch off.
    10. for HV Model:
      1. Turn the power switch off.
    11. for Gasoline Model:
      1. Disconnect the cable from the negative (-) battery terminal.
    12. for HV Model:
      1. Disconnect the cable from the negative (-) auxiliary battery terminal.
    13. for Driver Side:
      1. Disconnect the multiplex network master switch assembly.
    14. for Front Passenger Side:
      1. Disconnect the power window regulator switch assembly.
    15. Remove the 2 bolts.
      GTY868336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    16. Remove the front door glass sub-assembly as shown in the illustration.
      GTY869987Courtesy 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.

  34. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Disengage the 2 claws to remove the front door No. 2 service hole cover.
      GTY932818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector.
      GTY878853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporary Bolt
    3. 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.

    4. Remove the 5 bolts and front door window regulator assembly.
    5. Remove the temporary bolt from the front door window regulator assembly.
  35. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
      GTY868339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      GTY898448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration.
  37. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 2 bolts.
      GTY909899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Disengage the guide and remove the front door front lower frame sub-assembly as shown in the illustration.
  38. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Using a screwdriver, disengage the 2 claws as shown in the illustration.
      GTY849822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Disengage in this Direction
    2. Using a screwdriver, disconnect the connector.
      GTY932862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 3 clamps.
      GTY868546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 claws and move the lever as shown in the illustration.
      GTY877326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Disengage in this Direction
    5. Remove the front door outside handle assembly as shown in the illustration.
      GTY919005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  39. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
      GTY932865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door lock cylinder assembly.
      GTY868552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

  40. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Remove the hole plug.
      GTY868547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY868550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

    3. Disengage the 2 claws to remove the front door outside handle cover.
  41. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 2 claws and guide to remove the front door front outside handle pad.
      GTY868551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the claw and 3 guides to remove the front door rear outside handle pad.
      GTY868465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 21

  44. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the screw.
      GTY868466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw and guide to remove front door outside handle frame sub-assembly as shown in the illustration.
      GTY862165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  45. 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.
      GTY937359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  46. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the 2 nuts, bolt and front door check assembly.
      GTY892479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt
  47. REMOVE DOOR FRAME GARNISH 
    1. Disengage the 3 claws to remove the door frame garnish.
      GTY868473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 23 clips and remove the front door weatherstrip.
      GTY868472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE FRONT DOOR PANEL CUSHION 
    1. Disengage the 4 claws to remove the 2 front door panel cushions.
      GTY868470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Disengage the 8 clips to remove the front door No. 2 weatherstrip.
      GTY932847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE DOOR WINDOW FRAME MOULDING CLIP 
    1. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws to remove the door window frame moulding clip.
      GTY923913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
  52. REMOVE FRONT DOOR DUST PROOF SEAL 
    1. Disengage the claw to remove the front door dust proof seal.
      GTY932850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 15

  54. REMOVE FRONT DOOR FRONT LOWER FRAME UPPER COVER 

    Refer to PROCEDURE - Step 2

  55. REMOVE NO. 2 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 20

  56. REMOVE NO. 1 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 21

  57. REMOVE FRONT DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE) 

    Refer to PROCEDURE - Step 6

  58. REMOVE FRONT DOOR REAR OUTSIDE SEAL 
    1. Disengage the guide to remove the front door rear outside seal.
      GTY868484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 7

  60. REMOVE FRONT DOOR SILENCER PAD 
    1. Remove the 2 front door silencer pads.
      GTY882025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE FRONT DOOR NO. 3 WEATHERSTRIP 
    1. Disengage the 4 claws to separate the grommet.
      GTY844035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector.
    3. Remove the 4 bolts and front door panel sub-assembly.
      NOTE:

      To prevent damage, when removing the front door panel sub-assembly, make sure that there are enough people available to hold it securely.

      GTY844034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 clips and front door No. 3 weatherstrip.
      GTY868478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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