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Home >> Toyota >> 2021 >> Mirai XLE >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Door / Hatch - Service Information (1 Of 3) >> Front Door >> Disassembly [12/2022 - 12/2023] >> Procedure

Disassembly [12/2022 - 12/2023]: Procedure

  1. PRECAUTION 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [12/2022 - 12/2023]
  2. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to REMOVAL [12/2022 - 12/2023]

  3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. GTY1017937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using moulding remover A, detach the claw and remove the front door inside handle bezel plug.
  4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) 
    1. GTY1018194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Order - -
      1. Using moulding remover A, detach the claws as shown in the illustration and remove the power window regulator switch assembly with front door armrest base panel.
      2. Disconnect the connector.
  5. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) 
    1. GTY1018217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Order - -
      1. Using moulding remover A, detach the claws as shown in the illustration and remove the power window regulator switch assembly with front door armrest base panel.
      2. Disconnect the connector.
  6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. GTY1018192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here Remove in this Direction
      Remove in this Order - -
      1. Remove the 3 screws.
      2. Place your hand at the position shown in the illustration, detach the clip.
      3. Pull the front door trim board sub-assembly shown in the illustration, detach the claws and guides and remove the front door trim board sub-assembly from the front door panel.
    2. GTY1017645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction Push
      1. Detach the clamps and disconnect the open lever front door lock remote control cable from the front door inside handle sub-assembly.
      2. Detach the claws and clamps, disconnect the lock/unlock knob front door inside locking cable.
      3. Disconnect the connectors.
  7. REMOVE COURTESY LIGHT ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  8. REMOVE SEAT MEMORY SWITCH (w/ Seat Memory Switch) 

    Refer to PROCEDURE - Step 4

  9. REMOVE NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 5

  10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. GTY1017164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  11. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. GTY1017071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  12. REMOVE FRONT DOOR GLASS INNER WEATHERSTRIP 
    1. GTY1018117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Using a clip remover with its tip wrapped in protective tape, detach the clips.
      2. Turn over the front door glass inner weatherstrip partially.
      3. Remove the front door glass inner weatherstrip with front door belt rear seal.
  13. REMOVE FRONT DOOR BELT REAR SEAL 
    1. GTY1017431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  14. REMOVE FRONT DOOR BELT FRONT SEAL 
    1. GTY1017700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  15. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 5
  16. REMOVE MULTIPLEX NETWORK FRONT DOOR ECU 
    1. GTY1018376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the 4 connectors.
      2. Detach the clamp.
        NOTE:

        Be sure to replace the clamps with a new one when disconnecting, for they are non-reusable part.

      3. Remove the 2 screws and remove the multiplex network front door ECU.
      4. Remove the 2 grommets.
  17. REMOVE HOLE PLUG 
    1. GTY1017958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT DOOR NO. 2 SERVICE HOLE COVER 
    1. GTY1018103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 8

  20. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. GTY1018228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Turn the service hole cover clip 45° to remove the 3 service hole cover clips as shown in the illustration.
      2. Using a clip remover with its tip wrapped in protective tape, detach the clips and remove the front door service hole cover.
      3. Pull out the front door lock remote control cable assembly and front door inside locking cable assembly from the front door service hole cover as shown in the illustration.
  21. REMOVE SIDE AIRBAG PRESSURE SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 8

  22. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. GTY1018281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the multiplex network front door ECU.
      2. for Driver Side:

        1. Connect the power window regulator master switch assembly with front door armrest base panel.

      3. for Front Passenger Side:

        1. Connect the power window regulator switch assembly with front door armrest base panel.

      4. Connect the 2 connectors to temporarily install the front door trim board sub-assembly.
      5. Connect the cable to the negative (-) auxiliary battery terminal and turn the ignition switch on.
      6. Move the door glass until the bolts appear in the service holes and turn the ignition switch off.
    2. GTY1018010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the cable from the negative (-) battery terminal.
        WARNING:
        • Wait at least 60 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
        • If an SRS part is accidentally deployed, it may cause a serious injury.
      2. Disconnect the 2 connectors to remove the front door trim board sub-assembly.
      3. For Driver Side:

        1. Disconnect the power window regulator master switch assembly with front door armrest base panel.

      4. For Front Passenger Side:

        1. Disconnect the power window regulator switch assembly with front door armrest base panel.

      5. Disconnect the multiplex network front door ECU.
    3. GTY1018338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1) Remove in this Direction (2)
      1. Remove the 2 bolts.
      2. Remove the front door glass sub-assembly as shown in the illustration.
        NOTE:

        Do not damage the front door glass.

  23. REMOVE FRONT DOOR GLASS RUN 
    1. GTY1016582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. GTY1017009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  25. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. GTY1016408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  26. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. GTY1018221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut Connector
  27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. GTY1164159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Using a screwdriver with its tip wrapped in protective tape, disengage the claws.
      2. Using a screwdriver with its tip wrapped in protective tape, disengage the claws and disconnect the connector.
      3. Disengage the claws and move the lever as shown in the illustration.
      4. Remove the front door outside handle assembly as shown in the illustration.
  28. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. GTY1017944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Remove the hole plug.
      2. Using a T30 "TORX" socket wrench, loosen the TORX screw and remove the front door lock cylinder assembly LH.
  29. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. GTY1017925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Remove the hole plug.
      2. Using a T30 "TORX" socket wrench, loosen the screw to remove the front door outside handle cover.
  30. REMOVE FRONT DOOR OUTSIDE HANDLE FRONT PAD 
    1. GTY1017228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  31. REMOVE FRONT DOOR OUTSIDE HANDLE REAR PAD 
    1. GTY1016767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  32. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. GTY1018119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1) Remove in this Direction (2)
      1. Detach the snap and remove the front door lock open rod as shown in the illustration.
      2. Using a T30 "TORX" socket wrench, loosen the screw.
      3. Detach the wire harness clamps.
      4. Detach the guide and remove the front door outside handle frame sub-assembly.
  33. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 21
  34. REMOVE FRONT DOOR LOCK OPEN ROD 

    Refer to PROCEDURE - Step 22

  35. REMOVE FRONT DOOR LOCK COVER SUB-ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 23
  36. REMOVE FRONT DOOR LOCK OPEN LEVER REMOTE CONTROL CABLE 

    Refer to PROCEDURE - Step 24

  37. REMOVE FRONT DOOR INSIDE LOCK/UNLOCK KNOB LOCKING CABLE 

    Refer to PROCEDURE - Step 25

  38. REMOVE DOOR LOCK WIRING HARNESS SEAL 
    1. When reusing the front door lock assembly:
      GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 Refer to PROCEDURE - Step 26
  39. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. GTY1017094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut Bolt
  40. REMOVE UPPER DOOR FRAME GARNISH 
    1. GTY1017187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  41. REMOVE FRONT DOOR WEATHERSTRIP 
    1. GTY1018212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a clip remover with its tip wrapped in protective tape, detach the clip.
    2. GTY1167666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape - -
      Double-sided Tape - -
      1. Heat the front door weatherstrip using a heat light.
        WARNING:
        GTY812772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Heated Part
        *b Heat Light
        • Do not touch the heat light and heated parts.
        • Touching the heat light may result in burns.
        • Touching heated parts for a long time may result in burns.

        Standard Value

        Part Temperature
        Front door weatherstrip 20 to 30°C (68 to 86°F)
      2. Remove the double-sided tape and using a clip remover, disengage the clip.
      3. Detach the clips and remove the front door weatherstrip.
  42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 1
  43. REMOVE FRONT DOOR WINDOW FRAME MOULDING 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 4
  44. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 5
  45. REMOVE FRONT DOOR FRONT LOWER FRAME UPPER COVER 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 2
  46. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP 
    1. GTY1018337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a clip remover with its tip wrapped in protective tape, disengage the claws to remove the front door No. 2 weatherstrip.
  47. REMOVE FRONT DOOR PANEL CUSHION 
    1. GTY1016615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FRONT DOOR NO. 3 STRIPE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 16
  49. REMOVE FRONT DOOR NO. 4 STRIPE 
    GTY993405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    		 Refer to PROCEDURE - Step 15
  50. REMOVE FRONT DOOR NO. 3 WEATHERSTRIP 
    1. GTY1164420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Apply protective tape around the front door No. 3 weatherstrip as shown in the illustration.
      2. Heat the front door No. 3 weatherstrip using a heat light.
        WARNING:
        GTY812772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Heated Part
        *b Heat Light
        • Do not touch the heat light and heated parts.
        • Touching the heat light may result in burns.
        • Touching heated parts for a long time may result in burns.

        Standard Value

        Part Temperature
        Front door No. 3 weatherstrip 20 to 30°C (68 to 86°F)
      3. Using a clip remover, remove the clips.
      4. Remove the double-sided tape and front door No. 3 weatherstrip as shown in the illustration.
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