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Home >> Toyota >> 2021 >> RAV4 TRD Off-Road >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) - Service Information (1 Of 4) >> Front Door >> Disassembly [08/2020 - 12/2021] >> Procedure

Disassembly [08/2020 - 12/2021]: Procedure

  1. PRECAUTION 
    WARNING:

    Be sure to read Precaution thoroughly before servicing.

    Refer to PRECAUTION [08/2020 - ]

    GTY824211Courtesy 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. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2018 - ]

  2. REMOVE DECK BOARD ASSEMBLY (for HV Model) 

    Refer to PROCEDURE - Step 2

  3. REMOVE REAR NO. 2 FLOOR BOARD (for HV Model) 

    Refer to PROCEDURE - Step 3

  4. REMOVE BATTERY HOLE COVER (for HV Model) 

    Refer to PROCEDURE - Step 4

  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 
    1. for A25A-FXS:

      Refer to PROCEDURE - Step 5

    2. for A25A-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 the airbag deploys for any reason, it may cause a serious accident.
      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 [08/2020 - 12/2021]

  6. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH 
    1. Detach the claw and remove the front door inside handle bezel LH.
      GTY878788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FRONT DOOR ASSIST GRIP COVER LH 
    1. Apply protective tape to the front door trim board sub-assembly LH as shown in the illustration.
      GTY892183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a moulding remover A, detach the clip.
      GTY899581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Detach the claw in the order shown in the illustration.
    4. Detach the guide in the direction indicated by the arrow shown in the illustration and remove the front door assist grip cover LH.
      GTY905533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  8. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) 
    1. Apply protective tape around the multiplex network master switch assembly with front door armrest base panel.
      GTY910929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a moulding remover A, detach the guide and claw as shown in the illustration.
      GTY917010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Detach the guide in the direction indicated by the arrow shown in the illustration and remove the multiplex network master switch assembly with front door armrest base panel.
      GTY922850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    4. Disconnect the 2 connectors.
  9. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side) 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 2

  11. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) 
    1. Apply protective tape around the power window regulator switch assembly with front door armrest base panel.
      GTY842273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a moulding remover A, detach the guide and claw as shown in the illustration.
      GTY848177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    3. Detach the guide in the direction indicated by the arrow shown in the illustration and remove the power window regulator switch assembly with front door armrest base panel.
      GTY849411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
    4. w/ Door Control Switch:
      1. Disconnect the 2 connectors.
    5. w/o Door Control Switch:
      1. Disconnect the connector.
  12. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) 

    Refer to PROCEDURE - Step 2

  13. REMOVE DOOR CONTROL SWITCH ASSEMBLY (w/ Door Control Switch) 

    Refer to PROCEDURE - Step 2

  14. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH 
    1. Apply protective tape to the front door panel as shown in the illustration.
      GTY843309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Remove the 3 screws.
      GTY882285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place your hand at the position shown in the illustration, and while pulling the front door trim board sub-assembly LH toward you, detach the clip and disconnect the front door trim board sub-assembly LH from the front door panel.
      GTY850601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here
      Remove in this Direction

      HINT: 

      • Detach the clip in the order shown in the illustration.
      • Securely detach the clips one by one.
    4. Pull the front door trim board sub-assembly LH in the direction indicated by the arrow shown in the illustration to detach the claw and clip to remove the front door trim board sub-assembly LH.
      GTY932241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction

      HINT: 

      Detach the claw and clips in the order shown in the illustration.

    5. Detach the clamp and disconnect the front door lock remote control cable assembly and front door inside locking cable assembly as shown in the illustration.
      GTY862435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
      Remove in this Direction
    6. w/ Seat Memory Switch:
      GTY882268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the connector.
  15. REMOVE SEAT MEMORY SWITCH (w/ Seat Memory Switch) 

    Refer to PROCEDURE - Step 5

  16. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH 
    1. Detach the clamp and claw.
      GTY882262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the front door inside handle sub-assembly LH in the direction indicated by the arrow as shown in the illustration.
      GTY933966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  17. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP LH 
    1. Using a clip remover with its tip wrapped with protective tape, detach the clip.
      GTY889639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
      Protective Tape
    2. Detach the guide and roll up the front door weatherstrip LH enough that the front door inner glass weatherstrip LH can be removed.
    3. Remove the front door inner glass weatherstrip LH with front door rear belt seal LH as shown in the illustration.
      GTY912255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  18. REMOVE FRONT DOOR REAR BELT SEAL LH 
    1. Remove the front door rear belt seal LH from the front door inner glass weatherstrip LH as shown in the illustration.
      GTY906417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  19. REMOVE FRONT DOOR FRONT BELT SEAL LH 
    1. Using a clip remover with its tip wrapped with protective tape, detach the clip.
      GTY945509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
      Protective Tape
    2. Detach the guide and roll up the front door weatherstrip LH enough that the front door front belt seal LH can be removed.
    3. Remove the front door front belt seal LH as shown in the illustration.
      GTY944008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  20. REMOVE OUTER MIRROR INSTALL HOLE COVER LH 

    Refer to PROCEDURE - Step 6

  21. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  22. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  23. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    1. Disconnect the connector.
      GTY935882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the clamp.
    3. Check that the service hole cover clip knob and bead mark are aligned.
      GTY926481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Location Mark
      *b Bead Mark
      Turn in this Direction
      Service Hole Cover Clip
    4. Turn the service hole cover clip 45° clockwise to the location mark and then remove the service hole cover clip.

      HINT: 

      Use the same procedure for the other service hole cover clips.

    5. Using a clip remover with its tip wrapped with protective tape, detach the clip.
      GTY855217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    6. Pull out the front door lock remote control cable assembly LH and front door inside locking cable assembly LH from the front door service hole cover LH.
      GTY929232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  24. REMOVE SIDE AIRBAG PRESSURE SENSOR LH 

    Refer to PROCEDURE - Step 12

  25. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH 
    1. Remove the hole plug.
      GTY935881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Driver Side:
      1. Connect the multiplex network master switch assembly connector.
    3. for Front Passenger Side:
      1. Connect the power window regulator switch assembly connector.
    4. Connect the cable to the negative (-) auxiliary battery terminal.
      1. for A25A-FXS:

        Refer to PROCEDURE - Step 2

      2. for A25A-FKS:

        Refer to PROCEDURE - Step 2

    5. Turn the ignition switch to ON.
    6. Move the front door glass sub-assembly LH until the installation bolts can be seen.
    7. Turn the ignition switch off.
    8. Disconnect the cable from the negative (-) auxiliary battery terminal.
      1. for A25A-FXS:

        Refer to PROCEDURE - Step 5

      2. for A25A-FKS:

        Refer to REMOVAL [08/2020 - 10/2022]

        WARNING:
        GTY581108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • After disconnecting the cable from the negative (-) auxiliary battery terminal, wait for at least 90 seconds to start the operation.
        • If the airbag deploys for any reason, it may cause a serious accident.
    9. for Driver Side:
      1. Disconnect the multiplex network master switch assembly connector.
    10. for Front Passenger Side:
      1. Disconnect the power window regulator switch assembly connector.
    11. Apply protective tape around the front door panel as shown in the illustration.
      GTY861552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    12. Remove the 2 bolts.
      GTY882333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    13. Remove the front door glass sub-assembly LH in the direction indicated by the arrows, in the order shown in the illustration.
      GTY884356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
      NOTE:

      Be careful not to damage the front door glass sub-assembly LH.

  26. REMOVE DOOR FRAME GARNISH LH 
    1. Detach the guide and remove the door frame garnish LH in the direction indicated by the arrows, in the order shown in the illustration.
      GTY901479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  27. REMOVE FRONT DOOR GLASS RUN LH 
    1. Remove the front door glass run LH as shown in the illustration.
      GTY938642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
  28. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 
    1. Disconnect the connector.
      GTY914012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Connector
    2. Remove the 7 nuts and the front door window regulator sub-assembly LH.
      NOTE:

      Do not damage the front door panel with the front door window regulator sub-assembly LH.

      HINT: 

      When removing the front door window regulator assembly LH, pull it out from the service hole as shown in the illustration.

      GTY907986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  29. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 

    Refer to PROCEDURE - Step 16

  30. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH 
    1. Remove the bolt.
      GTY882288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Detach the guide and remove the front door rear lower frame sub-assembly LH.
  31. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH 
    1. Lift up the front door weatherstrip LH and remove the screw as shown in the illustration.
      GTY915117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lift up in this Direction
    2. Remove the screw.
    3. Remove the 3 bolts.
      GTY844531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1)
      Remove in this Direction (2)
    4. Remove the front door front lower frame sub-assembly LH in the direction indicated by the arrows, in the order shown in the illustration.
  32. REMOVE FRONT DOOR FIX WINDOW GLASS LH 
    1. Remove the front door fix window glass LH as shown in the illustration.
      GTY840978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  33. REMOVE FRONT DOOR BELT MOULDING LH 

    Refer to PROCEDURE - Step 19

  34. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH 
    1. w/ Smart Key System:
      GTY862506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
      Protective Tape
      1. Using a screwdriver with its tip wrapped with protective tape, detach the claw and open the connector cover as shown in the illustration.
      2. Using a screwdriver with its tip wrapped with protective tape, detach the claw to disconnect the connector and connector cover as shown in the illustration.
        GTY877016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Protective Tape
    2. Detach the holder as shown in the illustration.
      GTY871597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Holder
      Remove in this Direction
    3. Remove the front door outside handle assembly LH by sliding and pulling it in the direction indicated by the arrow in the illustration.
      GTY933972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  35. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY LH (for Driver Side) 
    1. Remove the hole plug.
      GTY882305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the "TORX" screw.
      GTY882306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the front door lock cylinder assembly LH as shown in the illustration.
      GTY902988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  36. REMOVE FRONT DOOR OUTSIDE HANDLE COVER RH (for Front Passenger Side) 
    1. Remove the hole plug.
      GTY882407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, loosen the "TORX" screw.
      GTY882408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Detach the claw and remove the front door outside handle cover RH as shown in the illustration.
      GTY904516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction
  37. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Detach the claw and guide to remove the front door front outside handle pad.
      GTY882428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Detach the guide and remove the front door rear outside handle pad.
      GTY882429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FRONT DOOR LOCK OPEN ROD LH 
    1. Detach the snap as shown in the illustration.
      GTY852058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Snap
      Remove in this Direction (1)
      Remove in this Direction (2)
      Remove in this Direction (3)
    2. Remove the front door lock open rod LH in the direction indicated by the arrow shown in the illustration.
  40. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Using a T30 "TORX" socket wrench, loosen the "TORX" screw.
      GTY867151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Inside
      *b Outside
    2. Detach the guide and remove the front door outside handle frame sub-assembly LH.
    3. w/ Smart Key System:
      GTY882423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Detach the wire harness clamp.
  41. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY LH 

    Refer to PROCEDURE - Step 23

  42. REMOVE DOOR LOCK WIRING HARNESS SEAL 
    1. When reusing front door lock with motor assembly LH:

      Refer to PROCEDURE - Step 24

  43. REMOVE FRONT DOOR LOCK COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 25

  44. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 26

  45. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 27

  46. REMOVE FRONT DOOR CHECK ASSEMBLY LH 
    1. Remove the 2 bolts (A), bolt (B) and front door check assembly LH.
      GTY921345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
      Bolt (B)
  47. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a clip remover with its tip wrapped with protective tape, detach the clip.
      GTY915156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
    2. Using a screwdriver with its tip wrapped with protective tape, detach the clip and remove the front door weatherstrip LH.
      GTY844569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Protective Tape
  48. REMOVE FRONT DOOR WINDOW FRAME MOULDING LH (CENTER PILLAR SIDE) 

    Refer to PROCEDURE - Step 21

  49. REMOVE FRONT DOOR PANEL PROTECTOR LH 

    Refer to PROCEDURE - Step 22

  50. REMOVE DOOR WINDOW FRAME MOULDING CLIP 
    1. Detach the claw and remove the door window frame moulding clip.
      GTY893211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Perform the following procedure only when replacement of a door window frame moulding clip in necessary.

  51. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING LH 

    Refer to PROCEDURE - Step 23

  52. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP LH 
    1. Using a screwdriver with its tip wrapped with protective tape, detach the clip and remove the front door No. 2 weatherstrip LH.
      GTY935901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE FRONT DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  54. REMOVE SCREW GROMMET 
    1. Detach the claw and remove the screw grommet.
      GTY882398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use the same procedure described for the other side.

  55. REMOVE HOLE PLUG 
    1. Remove the hole plug.
      GTY882402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use the same procedure described for the other side.

  56. REMOVE FRONT DOOR PANEL CUSHION 
    1. Detach the claw and remove the front door panel cushion.
      GTY882401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Use the same procedure described for the other side.

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