Front Door: Disassembly

1. Using a screwdriver, remove the cover.

   HINT:

   Tape the screwdriver tip before use.

2. Remove the screw.
3. Using a screwdriver, remove the inside handle bezel as shown in Fig 1 .

   HINT:

   Tape the screwdriver tip before use.

1. Using a screwdriver, remove the upper armrest base panel with power window switch.

   HINT:

   Tape the screwdriver tip before use.

2. Disconnect the connector.
3. Remove the 3 screws and power window switch from the upper armrest base panel.

Fig 2: Removing Upper Armrest Base Panel With Power Window Switch

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1. Using a screwdriver, remove the 2 caps.

   HINT:

   Tape the screwdriver tip before use.

2. Remove the 6 screws and clip.
3. Pull the trim upward to remove it.
   Fig 3: Removing Door Trim

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4. Using a screwdriver, remove the front door inner weatherstrip from the front door trim.
5. Remove the 10 screws and front door armrest from the front door trim.
6. Remove the 8 screws and front door trim pocket from the front door trim.

Fig 4: Removing Front Door Trim Pocket And Front Door Armrest From Front Door Trim

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Using a screwdriver, remove the lower frame bracket as shown in Fig 5 .

HINT:

Tape the screwdriver tip before use.

Torque: 7.8 N.m (80 Kgf.cm, 69 ft.lbf) 

1. Remove the screw.
2. Slide the inside handle backward to remove it.
   Fig 5: Removing Lower Frame Bracket

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3. Disconnect the 2 cables from the inside handle as shown in Fig 6 .

Fig 6: Disconnecting Cables From Inside Handle

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1. Using a clip remover, remove the grommets.
2. Remove the service hole cover.
   NOTE: Do not tear the cover.

   HINT:

   At the time of reassembly, please refer to the following item. Bring out the 2 control cables and wire harness through the service hole cover.

Fig 7: Removing Service Hole Cover

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1. Using a clip remover, remove the clip.
2. Remove the screw from the door check.
3. Using a clip remover, remove the front door weatherstrip.
4. Reinstall the screw to the door check.

   Torque: 25 N.m (260 Kgf.cm, 19 ft.lbf) 

Fig 8: Removing Front Door Weatherstrip

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1. Apply protective tape to the outer surface as shown in Fig 9 , to keep the surface from being scratched.
2. Using a moulding remover, remove the front door belt moulding.

Fig 9: Removing Front Door Belt Moulding

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1. Using a drill of less than 03.2 mm (0.126 in.), drill out the 3 rivet heads.

   HINT:

   Gently and vertically put the drill to the rivets, and cut the rivet flanges.

   CAUTION: Take care as the cut rivets are hot.
   NOTE: Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
2. Using a clip remover, remove the clip.
3. Remove the front door outside lower moulding.
4. Using a vacuum cleaner, remove the drilled rivets and associated metallic dust from the inside of door panel.

   HINT:

   At the time of reassembly, please refer to the following item. Using an air riveter with nose piece No. 1 or a hand riveter with nose piece No. 1 to install new 3 rivets to the front door outside lower moulding.

   Fig 10: Removing Front Door Outside Lower Moulding

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE:

   • At the time of reassembly, please refer to the following items.
   • Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
     Fig 11: Precautions While Installing Rivets (1 Of 3)

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   • Do not tilt the riveter disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
     Fig 12: Precautions While Installing Rivets (2 Of 3)

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   • Install the rivet while attaching materials, as they are not tightened firmly.
     Fig 13: Precautions While Installing Rivets (3 Of 3)

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Remove the window regulator connector clamp, 3 screws and No. 2 service hole cover.

1. Open the door glass until the bolts appear in the service hole.
2. Remove the 2 bolts.

   Torque: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

   NOTE: Be careful not to drop the door glass.
3. Pull the door glass upward to remove it.

1. Disconnect the connector, then remove the bolt, 3 nuts and window regulator assembly.

   Torque: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

   HINT:

   Remove the window regulator assembly through the service hole.

2. Using a torx driver, remove the 3 torx screws and window regulator motor from the window regulator guide assembly.

   HINT:

   At the time of reassembly, please refer to the following items.

   • Apply MP grease to the glass guide and rollers of window regulator assembly.
   • After installing the window regulator assembly, window regulator assembly need to be re-initialized

   Refer to ADJUSTMENT .

1. Disconnect the 2 control links from the outside handle and door lock cylinder.
2. Disconnect the connector.
3. Remove the 3 torx screws, bolt and door lock.

   Torque: 

   Bolt: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

   Screw: 4.9 N.m (50 Kgf.cm, 43 in.lbf) 

   HINT:

   Remove the door lock through the service hole.

   HINT:

   At the time of reassembly, please refer to the following item.

   Apply adhesive to 3 screws.

   Part No. 08833-00070, THREE BOND 1324 or equivalent 

4. Remove the 2 screws and door lock protector from the door lock.

   HINT:

   At the time of reassembly, please refer to the following item

   Apply MP grease to the sliding and rotating parts of the door lock.

1. Remove the 2 bolts and outside handle with key cylinder.

   Torque: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

2. Remove the bolt and key cylinder from the outside handle.

   Torque: 5.4 N.m (55 Kgf.cm, 48 in.lbf) 

Fig 15: Applying MP Grease To Sliding And Rotating Parts Of Door Lock

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