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Home >> Toyota >> 2021 >> Prius Prime XLE >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (1 Of 2) >> Front Door >> Disassembly [09/2016 - 07/2020] >> Procedure

Disassembly [09/2016 - 07/2020]: Procedure

  1. PRECAUTION 
    WARNING:

    Be sure to read Precaution thoroughly before servicing.

    Refer to PRECAUTION [09/2016 - 05/2019] , or refer to PRECAUTION [05/2019 - 07/2020]

    GTY607029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 [09/2016 - 01/2018] , or refer to PRECAUTION [01/2018 - 05/2019] , or refer to PRECAUTION [05/2019 - ]

  2. 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
    NOTE:

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

    Refer to INITIALIZATION [09/2016 - 05/2019] , or refer to INITIALIZATION [05/2019 - 07/2020]

  3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Using a molding remover, disengage the 3 claws to remove the front door inside handle bezel plug.
      GTY604555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT ARMREST ASSEMBLY 
    1. Disengage the 3 clips and 7 claws as shown in the illustration.
      GTY604359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction
    2. Disengage the guide to remove the front armrest assembly as shown in the illustration.
      GTY588202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  5. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. Disengage the 2 clips and 4 claws as shown in the illustration.
      GTY546654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction
    2. Disconnect the connector to remove the multiplex network master switch assembly with front door upper armrest base panel.
  6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side) 
    1. Disengage the 2 clips and 4 claws as shown in the illustration.
      GTY543140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction
    2. Disconnect the connector to remove the power window regulator switch assembly with front door upper armrest base panel.
  7. REMOVE COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Apply protective tape to the front door panel as shown in the illustration.
      GTY599392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Remove the 3 screws.
      GTY592977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 clips.
      GTY543272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a clip remover, disengage the 10 clips.
      GTY702473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. While pulling out the front door trim board sub-assembly, insert a hand between the front door trim board sub-assembly and front door panel up to the area where the claws are engaged.
      GTY738298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. While pulling down the part of the front door inner glass weatherstrip shown in the illustration, pull out the front door trim board sub-assembly to disengage the 2 claws.
      GTY688542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
    7. Using a clip remover, disengage the clip.
      GTY702459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Engage the 2 claws.
      GTY702461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Pull out the front door trim board sub-assembly to disengage the guide from the front door panel.
      GTY1013705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Lift the front door trim board sub-assembly to separate the front door trim board sub-assembly with the front door inner glass weatherstrip from the front door panel.
      NOTE:

      To prevent damage to the guide, lift the front door trim board sub-assembly with the guide disengaged.

    11. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly to remove the front door trim board sub-assembly as shown in the illustration.
      GTY719723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
      Remove in this Direction
  9. REMOVE FRONT DOOR VENT SEAL 
    1. Remove the front door vent seal from the front door inner glass weatherstrip as shown in the illustration.
      GTY739105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  10. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Slide the front door inner glass weatherstrip to remove it from the front door trim board sub-assembly as shown in the illustration.
      GTY728380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    GTY592967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disengage the 2 claws to remove the front door inside handle sub-assembly.
  12. REMOVE FRONT DOOR PANEL PROTECTOR 

    Refer to PROCEDURE - Step 9

  13. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 10

  14. REMOVE FRONT DOOR NO. 3 SERVICE HOLE COVER 
    1. Remove the front door No. 3 service hole cover.
      GTY592602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  16. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. Turn each front door weatherstrip clip 45 degrees and remove the 3 front door weatherstrip clips as shown in the illustration.
      GTY609681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 4 clips to remove the front door service hole cover.
      GTY592954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE DOOR SIDE AIRBAG SENSOR 

    Refer to PROCEDURE - Step 12

  18. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Remove the hole plug.
      GTY592952Courtesy 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. Connect the cable to the negative (-) auxiliary battery terminal.
    5. Turn the power switch on (IG).
    6. Move the front door glass sub-assembly so that the door glass bolts can be seen.
    7. Turn the power switch off.
    8. Disconnect the cable from the negative (-) auxiliary battery terminal.
    9. for Driver Side:
      1. Disconnect the multiplex network master switch assembly.
    10. for Front Passenger Side:
      1. Disconnect the power window regulator switch assembly.
    11. Remove the 2 bolts.
      GTY609679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    12. Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.
      GTY607656Courtesy 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.

  19. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Disengage the 2 claws to remove the front door No. 2 service hole cover.
      GTY592947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector.
      GTY543954Courtesy 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.
    5. Remove the front door window regulator assembly.
    6. Remove the temporary bolt from the front door window regulator assembly.
  20. REMOVE FRONT DOOR GLASS RUN 
    1. Remove the front door glass run.
      GTY592942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Remove the bolt.
      GTY587037Courtesy 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.
  22. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Disengage the 2 claws.
      GTY609609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disconnect the connector.
    3. Disengage the 3 clamps.
      GTY609605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the 2 claws and move the lever as shown in the illustration.
      GTY547612Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Disengage in this Direction
    5. Remove the front door outside handle assembly as shown in the illustration.
      GTY602793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  23. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Remove the hole plug.
      GTY553081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door lock cylinder assembly.
      GTY592635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Remove the hole plug.
      GTY553082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the screw.
      GTY592634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the 2 guides and claw and remove the front door outside handle cover.
  25. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Disengage the 3 claws to remove the front door front outside handle pad.
      GTY592625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Disengage the 3 guides and claw to remove the front door rear outside handle pad.
      GTY592624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 17

  28. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using a T30 "TORX" socket wrench, remove the screw.
      GTY580764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Inside
      *B Outside
    2. Slide the front door outside handle frame sub-assembly to disengage the claw and remove the front door outside handle frame sub-assembly.
  29. 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.
      GTY585445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  30. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. Remove the 3 bolts and front door check assembly.
      GTY592617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.
      GTY592616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE DOOR FRAME GARNISH 
    1. Disengage the 3 claws to remove the door frame garnish.
      GTY592966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Remove the 3 bolts, screw and front door front lower frame sub-assembly.
      GTY546271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
  34. REMOVE FRONT DOOR FIX WINDOW GLASS 
    1. Remove the front door fix window glass with front door fix window weatherstrip as shown in the illustration.
      GTY553325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    2. Remove the front door fix window glass from the front door fix window weatherstrip.
  35. REMOVE FRONT DOOR PANEL CUSHION 
    1. Disengage the 4 claws to remove the 2 front door panel cushions.
      GTY592603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR DUST PROOF SEAL 
    1. Disengage the 3 claws to remove the 3 front door dust proof seals.
      GTY609600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE FRONT DOOR BELT MOLDING ASSEMBLY 

    Refer to PROCEDURE - Step 16

  38. REMOVE FRONT DOOR REAR WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 2

  39. REMOVE FRONT DOOR UPPER WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 7

  40. REMOVE FRONT DOOR REAR OUTSIDE STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 21

  41. REMOVE FRONT DOOR STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 22

  42. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 23

  43. REMOVE FRONT DOOR SCUFF PLATE 

    Refer to PROCEDURE - Step 10 [09/2016 - 05/2019] , or refer to PROCEDURE - Step 10 [05/2019 - 07/2020]

  44. REMOVE COWL SIDE TRIM BOARD 

    Refer to PROCEDURE - Step 11 [09/2016 - 05/2019] , or refer to PROCEDURE - Step 11 [05/2019 - 07/2020]

  45. REMOVE FRONT DOOR FRONT WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 10

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