Front Door: Disassembly

HINT:

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

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: Removing Regulator Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE INSIDE HANDLE BEZEL 
   1. Remove the screw.
   2. Using a screwdriver, pry out the bezel.

   HINT:

   Tape the screwdriver tip before use.

   Fig 2: Removing Inside Handle Bezel

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 

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

   HINT:

   Tape the screwdriver tip before use.

   Fig 3: Removing Front Door Lower Frame Bracket Garnish

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. w/ Power window: REMOVE POWER WINDOW SWITCH 

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

   HINT:

   Tape the screwdriver tip before use.

   Fig 4: Removing Power Window Switch (W/ Power Window)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
   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.

      Fig 5: Removing Door Trim Board

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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

       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.
       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.
       Fig 7: Removing Door Speaker

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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

       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.

    3. w/ Power window:

       Disconnect the connector.

    4. Remove the regulator through the service hole.
       Fig 9: Removing Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE WINDOW REGULATOR MOTOR 
    1. Place matchmarks on the window regulator motor bracket and regulator gear.
    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.

    Fig 10: Removing Window Regulator Motor

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
17. REMOVE OUTSIDE HANDLE 

    Remove the 2 screws and outside handle.

    Fig 11: Removing Door Lock

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002