Front Door: Disassembly

HINT:

A bolt without a torque specification is shown in the standard bolt chart, (see STANDARD BOLT )

1. REMOVE INSIDE HANDLE BEZEL 
   1. Using a screwdriver, open the screw cap.

      HINT:

      Tape the screwdriver tip before use.

   2. Remove the screw.
   3. Using a screwdriver, remove the inside handle bezel as shown in the illustration.

   HINT:

   Tape the screwdriver tip before use.

   Fig 1: Removing Inside Handle Bezel

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE POWER WINDOW SWITCH 
   1. Using a screwdriver, remove the power window switch.

      HINT:

      Tape the screwdriver tip before use.

   2. Disconnect the connectors.
      Fig 2: Removing Power Window Switch

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT ARMREST 
   1. Remove the screw.
   2. Using a screwdriver, remove the front armrest as shown in the illustration.

      HINT:

   3. Tape the screwdriver tip before use.
      Fig 3: Removing Front Armrest

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE LOWER FRAME BRACKET GARNISH 

   Remove the lower frame bracket garnish.

   Fig 4: Removing Lower Frame Bracket Garnish

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE DOOR TRIM 
   1. Using a screwdriver, remove the courtesy light, then disconnect the connector.

      HINT:

      Tape the screwdriver tip before use.

   2. Using a screwdriver, disengage the clips, then pull the trim upward to remove it.

   HINT:

   Tape the screwdriver tip before use.

   Fig 5: Removing Door Trim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT NO.2 SPEAKER 
   1. Disconnect the 2 connectors.
   2. Remove the 2 bolts and front No.2 speaker.
7. REMOVE OUTSIDE REAR VIEW MIRROR 
   1. Disconnect the connector.
   2. Remove the bolt and outside rear view mirror.
      Fig 6: Removing Front No.2 Speaker

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT NO.1 SPEAKER 
   1. Disconnect the connector.
   2. Using a drill of less than 0 4 mm (0.16 in.), drill out the rivet heads and remove the speaker.
   3. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
      NOTE:

      • Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
      • Take care as the cut rivet is hot.
   4. Even if a flange is taken off, continue drilling and push out remaining fragments with the drill.
   5. Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door.
      Fig 7: Removing Front No.1 Speaker

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE INSIDE HANDLE 

   Remove the screw and inside handle, disconnect the 2 cables from the inside handle.

   Fig 8: Removing Inside Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE SERVICE HOLE COVER 
    1. Remove the 2 screws and door trim bracket.
    2. Remove the service hole cover.
11. REMOVE FRONT DOOR INSIDE PANEL PLATE 

    Remove the 2 screws and front door inside panel plate.

    Fig 9: Removing Service Hole Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE NO.2 SERVICE HOLE COVER 

    Remove the 2 screws and No.2 service hole cover.

    Fig 10: Removing No.2 Service Hole Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE FRONT DOOR BELT MOULDING 
    1. Remove a screw.
    2. Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched.
    3. Using a moulding remover, remove the front door belt moulding as shown in the illustration.
       Fig 11: Removing Front Door Belt Moulding

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE DOOR GLASS 

    HINT:

    Insert a shop rag inside the door panel to prevent scratching the glass.

    1. Open the door glass until the bolts appear in the service hole.
    2. Remove the 2 bolts and door glass.
    NOTE: Do not damage the door glass.

    HINT:

    Pull the glass upward to remove it.

    Fig 12: Removing Door Glass

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE WINDOW REGULATOR 
    1. Disconnect the connector and disengage the clamps.
    2. Remove the 6 bolts and window regulator.
16. REMOVE WINDOW REGULATOR MOTOR 
    1. Place matchmarks on the window regulator motor bracket and regulator gear.
    2. Remove the 3 screws and motor.
       Fig 13: Removing Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE DOOR GLASS RUN 
18. REMOVE REAR LOWER FRAME 

    Remove the bolt and rear lower frame.

19. REMOVE DOOR LOCK 
    1. Disconnect the 2 links from the outside handle and key cylinder.
    2. Remove the bolt and 2 screws.
    3. Using a Torx socket wrench, remove the 3 Torx screws and door lock.
       1. Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool) 
    4. Disconnect the connector.

    HINT:

    Remove the door lock through the service hole.

    Fig 14: Removing Door Lock

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE OUTSIDE HANDLE AND KEY CYLINDER 
    1. Remove the screw and hole cover.
    2. Remove the 2 bolts and outside handle with the key cylinder.
    3. Remove the retainer from the outside handle.
    4. Remove the bolt, key cylinder and protector from the outside handle.
21. REMOVE CUSHIONS 
    Fig 15: Removing Outside Handle And Key Cylinder

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002