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Home >> Toyota >> 2023 >> Prius LE >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Door / Hatch - Service Information (1 Of 2) >> Front Door >> Disassembly [12/2022 - 03/2023] >> Procedure

Disassembly [12/2022 - 03/2023]: Procedure

  1. PRECAUTION 
    NOTE:

    After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [12/2022 - ]
  2. REMOVE BATTERY SERVICE HOLE COVER ASSEMBLY (for M20A-FXS) 
    Refer to PROCEDURE - Step 2
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    1. for M20A-FXS:

      Refer to PROCEDURE - Step 3

    2. for 2ZR-FXE:

      Refer to PROCEDURE - Step 2

  4. REMOVE FRONT DOOR TRIM UPPER COVER 
    1. GTY1146498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a moulding remover, disengage the 3 claws to remove the front door trim upper cover.
  5. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. GTY1157550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Apply protective tape to the front door trim board sub-assembly as shown in the illustration.
      2. Using a moulding remover, disengage the clip and 6 claws.
      3. Disconnect the 2 connectors 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. GTY1141803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Apply protective tape to the front door trim board sub-assembly as shown in the illustration.
      2. Using a moulding remover, disengage the clip and 6 claws.
      3. Disconnect the connector to remove the power window regulator switch assembly with front door upper armrest base panel.
  7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. GTY1276479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. As the screws will be removed in the next procedure, disengage the 2 claws using a moulding remover and slide down the cover to the point that the screws can be removed as shown in the illustration.
    2. GTY1158881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 3 screws.
    3. GTY1139209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Place Hand Here Remove in this Direction
      1. Apply protective tape to the front door panel as shown in the illustration.
      2. Disengage the 10 clips as shown in the illustration.
      3. Disengage the 4 claws and guide as shown in the illustration.
      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 to remove the front door trim board sub-assembly.
  8. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. GTY1143158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  9. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. GTY1156679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE DOOR FRAME GARNISH 
    1. GTY1140710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a clip remover with its tip wrapped with protective tape, disengage the clip.
      2. Disengage the 3 claws to remove the door frame garnish.
  11. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. GTY1158593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  12. REMOVE FRONT DOOR PANEL PROTECTOR 
    1. GTY1144858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  13. REMOVE NO. 3 FRONT DOOR SERVICE HOLE COVER 
    1. GTY1156680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  15. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  16. REMOVE FRONT DOOR TRIM BRACKET 
    1. GTY1156782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT DOOR WEATHERSTRIP CLIP 
    1. GTY1141393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Turn each front door weatherstrip clip 45 degrees as shown in the illustration and remove the 2 front door weatherstrip clips.
  18. REMOVE FRONT DOOR SERVICE HOLE COVER 
    1. GTY1156684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE SIDE AIR BAG PRESSURE SENSOR 
    Refer to PROCEDURE - Step 7
  20. REMOVE HOLE PLUG 
    1. GTY1156665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY 
    1. GTY1153585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Driver Side *B for Front Passenger Side
      1. for Driver Side:

        1. Connect the multiplex network master switch assembly.

      2. for Front Passenger Side:

        1. Connect the power window regulator switch assembly.

      3. Connect the cable to the negative (-) auxiliary battery terminal and turn the ignition switch to ON.
      4. Move the front door glass sub-assembly so that the door glass bolts can be seen and turn the ignition switch off.
    2. GTY1139009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Driver Side *B for Front Passenger Side
      Remove in this Direction (1) Remove in this Direction (2)
      1. Disconnect the cable from the negative (-) auxiliary battery terminal.
      2. for Driver Side:

        1. Disconnect the multiplex network master switch assembly.

      3. for Front Passenger Side:

        1. Disconnect the power window regulator switch assembly.

      4. Remove the 2 bolts.
        NOTE:

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

      5. Remove the front door glass sub-assembly as shown in the illustration.
        NOTE:

        Do not damage the front door glass sub-assembly.

  22. REMOVE FRONT DOOR GLASS RUN 
    1. GTY1156669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. GTY1139385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. GTY1156670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. GTY1142453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Lift up the front door weatherstrip as shown in the illustration.
      2. Remove the 2 bolts, screw and front door front lower frame sub-assembly.
  26. REMOVE FRONT DOOR FIX WINDOW GLASS 
    1. GTY1146932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
  27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. GTY1149481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Disengage the clamp.
      2. Using a screwdriver with its tip wrapped with protective tape, disengage the 2 claws as shown in the illustration.
      3. Using a screwdriver with its tip wrapped with protective tape, disconnect the connector.
      4. Disengage the 2 claws and move the lever as shown in the illustration.
      5. Remove the front door outside handle assembly as shown in the illustration.
  28. REMOVE HOLE PLUG 
    1. GTY1139386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FRONT DOOR LOCK OPEN ROD 
    1. GTY1150886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction (1) Remove in this Direction (2)
      Remove in this Direction (3) - -
      1. Disengage the snap as shown in the illustration to disconnect the front door lock open rod.
      2. Remove the front door lock open rod in the direction indicated by the arrow (3) shown in the illustration.
  30. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY WITH CABLE 
    Refer to PROCEDURE - Step 14
  31. REMOVE DOOR LOCK WIRING HARNESS SEAL 
    Refer to PROCEDURE - Step 15
  32. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. GTY1159363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a T30 "TORX" socket wrench, loosen the screw and remove the front door lock cylinder assembly.

        HINT: 

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

  33. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. GTY1146493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a T30 "TORX" socket wrench, loosen the screw.

        HINT: 

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

      2. Disengage the 2 claws to remove the front door outside handle cover RH.
  34. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. GTY1139202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. GTY1156790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. GTY1140249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Remove in this Direction - -
      1. Using a T30 "TORX" socket wrench, remove the screw.
      2. Disengage the 2 guides to remove the front door outside handle frame sub-assembly as shown in the illustration.
  37. REMOVE FRONT DOOR CHECK ASSEMBLY 
    1. GTY1156792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FRONT DOOR WEATHERSTRIP 
    1. GTY1144545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a clip remover with its tip wrapped with protective tape, disengage the clip.
      2. Using a clip remover with its tip wrapped with protective tape, disengage the 20 clips and remove the front door weatherstrip.
  39. REMOVE HOLE PLUG 
    1. GTY1156795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE FRONT DOOR PANEL CUSHION 
    1. GTY1156796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE DOOR WINDOW FRAME MOULDING CLIP 
    1. GTY1156797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 2 FRONT DOOR SERVICE HOLE COVER 
    1. GTY1152731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE DOOR DUST PROOF SEAL 
    1. GTY1156777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 3 FRONT DOOR WEATHERSTRIP 
    1. GTY1156779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY 
    Refer to PROCEDURE - Step 5
  46. REMOVE FRONT DOOR WINDOW FRAME REAR MOULDING 
    Refer to PROCEDURE - Step 4
  47. REMOVE FRONT DOOR WINDOW FRAME UPPER MOULDING 
    Refer to PROCEDURE - Step 5
  48. REMOVE FRONT DOOR WINDOW FRAME FRONT MOULDING 
    Refer to PROCEDURE - Step 9
  49. REMOVE FRONT DOOR SILENCER PAD 
    1. GTY1156780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE FRONT DOOR REAR OUTSIDE SEAL 
    1. GTY1156781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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