Front Door: Disassembly

HINT:

A bolt without a torque specification is shown in the standard bolt chart. (See SPECIFIED TORQUE FOR STANDARD BOLTS )

1. w/o Power window: REMOVE REGULATOR HANDLE 

   Pull off the snap ring with a shop rag, and remove the regulator handle and plate.

Fig 1: Pulling Off Snap Ring With Shop Rag
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE INSIDE HANDLE BEZEL 
   1. Remove the screw.
   2. Using a screwdriver, pry out the bezel.
   Fig 2: Removing Inside Handle Bezel & Screw
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Tape the screwdriver tip before use.

3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 

   Using a screwdriver, remove the front door lower frame bracket garnish.

   Fig 3: Removing Front Door Lower Frame Bracket Garnish

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Tape the screwdriver tip before use.

4. W/Power window: REMOVE POWER WINDOW SWITCH 

   Using a screwdriver, remove the power window switch then disconnect the connector.

   Fig 4: Removing Power Window Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   Tape the screwdriver tip before use.

5. REMOVE DOOR TRIM BOARD 
   1. Using a screwdriver, remove the door assist grip cover.

      HINT:

      Tape the screwdriver tip before use.

   2. Remove the 2 screws and clip.
   Fig 5: Removing Door Trim Board & Screws
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Insert a screwdriver, between the door panel and door trim board to pry the door trim board loose.

      HINT:

      Tape the screwdriver tip before use.

   4. Remove the door trim board.
6. REMOVE DOOR INSIDE HANDLE 
   1. Remove the screw and inside handle.
   2. Disconnect the 2 cables from the inside handle.
7. REMOVE SERVICE HOLE COVER 
8. REMOVE FRONT DOOR WEATHERSTRIP 

   Using a screwdriver, remove the front door weatherstrip.

   HINT:

   Tape the screwdriver tip before use.

9. REMOVE OUTSIDE REAR VIEW MIRROR 
   1. Disconnect the connector.
   2. Remove the 3 bolts and outside rear view mirror.
10. REMOVE DOOR GLASS RUN 
11. REMOVE DOOR BELT MOULDING 
    1. Remove the screw.
    2. Using a moulding remover, remove the front door belt moulding.
    Fig 6: Removing Door Belt Moulding & Screw
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE DOOR SPEAKER 
    1. Disconnect the connector.
    2. Using a drill of less than diameter 4 mm (0.16 in.), drill out the rivet heads and remove the door speaker.
    3. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
       Fig 7: Drilling Out Rivets

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       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 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 panel.
13. REMOVE DOOR GLASS 
    1. Open the door glass until the bolts appear in the service hole.
    2. Remove the 2 glass mounting bolts.
       NOTE: Be careful not to drop the door glass.
    3. Pull up the door glass upward to remove it.
       Fig 8: Removing Door Glass & Mounting Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE WINDOW REGULATOR 
    1. W/o Power window:

       Remove the 5 bolts.

    2. W/Power window:

       Remove the 6 bolts.

    Fig 9: Removing Bolts For Window Regulator
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. w/Power window:

       Disconnect the connector.

    4. Remove the regulator through the service hole.
15. REMOVE WINDOW REGULATOR MOTOR 
    1. Place matchmarks on the window regulator motor bracket and regulator gear.
    Fig 10: Placing Matchmarks On Window Regulator Motor
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a Torx wrench, remove the 3 screws and motor.

    HINT:

    At the time of reassembly, please refer to the following item. Align the matchmarks on the regulator motor bracket and regulator gear.

    NOTE: If having rotated the motor only, reset the motor (See ADJUSTMENT ).

    HINT:

    Never rotate the motor to the down direction until the complete of the window glass installation.

16. REMOVE DOOR LOCK 
    1. Disconnect the link from the door lock.
    2. Remove the 5 screws and bolt.
    3. w/Power door lock:

       Disconnect the connector.

    4. Remove the door lock through the service hole.
    Fig 11: Removing Door Lock, Screws & Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE OUTSIDE HANDLE 

    Remove the 2 screws and outside handle.