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Front Door: Disassembly

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
    1. Using a screwdriver, detach the clip and claw, and remove the garnish.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Removing Front Door Lower Frame Bracket Garnish LH
      G04224649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ASSIST GRIP COVER LH 
    1. Using a screwdriver, detach the 11 claws and remove the grip cover.

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Removing Grip Cover LH
      G04224650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT ARMREST BASE PANEL UPPER LH 
    1. Driver's side:
      Fig 3: Removing Armrest Base Panel Upper LH Together With Window Regulator Master Switch
      G04224651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver, detach the clip and 4 claws, and remove the armrest base panel upper LH together with the window regulator master switch.

        HINT:

        Tape the screwdriver tip before use.

      2. Disconnect the switch connector.
      3. Remove the 3 screws and window regulator master switch from the armrest base panel upper LH.
      NOTE: Be careful when removing the screws as the master switch may fall and become damaged.
    2. Passenger's side:
      Fig 4: Removing Window Regulator Master Switch
      G04224652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver, detach the clip and 5 claws, and remove the armrest base panel upper RH together with the window regulator switch.

        HINT:

        Tape the screwdriver tip before use.

      2. Disconnect the switch connector.
      3. Using a screwdriver, detach the 2 claws and remove the power window regulator switch from the armrest base panel upper RH.

        HINT:

        Tape the screwdriver tip before use.

        NOTE: Be careful when detaching the claws as the switch may fall and become damaged.
  5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH 
    1. Prevent damage to the door panel by applying protective tape to the areas indicated by the arrows in the illustration.
    2. Remove the 2 screws.
    3. Using a screwdriver, detach the 9 clips.

      HINT:

      Tape the screwdriver tip before use.

      Fig 5: Detaching Front Door Trim Board Subassembly LH Clips And Screws
      G04224653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Prepare to remove the door trim by holding the locations indicated by the arrows in the illustration.
    5. Horizontally pull out the door trim to detach the 4 clips.
      NOTE: To prevent damage to the 2 pins, be sure to keep the door trim horizontal while removing it.
      Fig 6: Removing Front Door Trim Board Subassembly LH
      G04224654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH (See  REMOVAL  ) 
  7. REMOVE FRONT DOOR BELT MOULDING LH (See  REMOVAL  ) 
  8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (See  REMOVAL  ) 
  9. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH 
    1. Remove the weatherstrip inner.
      Fig 7: Removing Weatherstrip Inner
      G04224655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH 
    Fig 8: Removing Front Door Inside Handle Subassembly LH
    G04224656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, detach the claw.

      HINT:

      Tape the screwdriver tip before use.

    2. Move the inside handle in the direction indicated by the arrow mark in the illustration. This will release the claw and allow removal of the inside handle.
    3. Disconnect the 2 cables from the inside handle.
  11. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    1. w/ No. 2 speaker:

      Remove the screw and No. 2 speaker (see REMOVAL ).

    2. Remove the service hole cover.
      Fig 9: Removing Service Hole Cover
      G04224657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Remove the remaining tape on the door side.
  12. REMOVE SIDE AIRBAG SENSOR ASSEMBLY LH (w/Side Airbag System and Curtain Shield Airbag System) 
    1. Remove the 2 nuts and sensor.

      HINT:

      Remove the sensor through the service hole.

    Fig 10: Removing Nuts And Sensor
    G04224658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT DOOR NO. 1 STIFFENER CUSHION 
    1. Remove the 2 bolts and cushion.

      HINT:

      Remove the sensor through the service hole.

    Fig 11: Removing Front Door No. 1 Stiffener Cushion
    G04224659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH 

    HINT:

    Insert a cushion inside the door panel to prevent the glass from being scratched.

    Fig 12: Removing Front Door Glass Sub-Assembly LH Bolts
    G04224660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Driver's side:

      Temporarily install the window regulator master switch.

    2. Passenger's side:

      Temporarily install the power window regulator switch.

    3. Move the door glass until the 2 bolts appear in the service holes.
    4. Remove the 2 bolts.
      NOTE: Be careful when removing the bolts as the glass may fall and become damaged.
    5. Remove the door glass in the direction indicated by the arrow marks in the illustration.
      NOTE: Be careful not to damage the glass.
    6. Driver's side:

      Remove the window regulator master switch.

    7. Passenger's side:

    Remove the power window regulator switch.

    Fig 13: Removing Front Door Glass Sub-Assembly LH
    G04224661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 
    1. Disconnect the connector.
    2. Loosen bolt A.
    3. Remove the 5 bolts and regulator.

      HINT:

      Remove the window regulator through the service hole.

      Fig 14: Removing Front Door Window Regulator Sub-Assembly LH
      G04224662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.
    4. Remove bolt A.
  16. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT 
    1. Place matchmarks on the window regulator motor bracket and regulator gear.
      Fig 15: Identifying Matchmarks
      G04224663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T25 "torx" driver, remove the 3 screws and motor.
      Fig 16: Removing Power Window Regulator Motor Assembly LH Front
      G04224664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH 
    1. Remove the bolt and frame.

      HINT:

      Remove the frame through the service hole.

      NOTE: Be careful when removing the bolts as the frame may fall and become damaged.
      Fig 17: Removing Front Door Frame Sub-Assembly Rear Lower LH
      G04224665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Remove the hole plug.
    2. Using a T30 "torx" socket, loosen the screw and remove the cover with the door lock key cylinder installed.
    Fig 18: Identifying Hole Plug
    G04224666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT DOOR LOCK ASSEMBLY 
    1. Using a T30 "torx" socket, remove the 3 screws and the door lock.

      HINT:

      Remove the door lock through the service hole.

      NOTE: Be careful when removing the screws as the door lock may fall and become damaged.
      Fig 19: Removing Front Door Lock Assembly
      G04224667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH 
    1. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
      Fig 20: Removing Front Door Handle Assembly Outside LH
      G04224668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: If the bellcrank lever is not pulled and held when removing the handle, the bellcrank lever will interfere with the handle and become damaged.
  21. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Using a T30 "torx" socket, loosen the screw of the frame.
      Fig 21: Loosening Front Door Outside Handle Frame Sub-Assembly LH Screws
      G04224669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using pliers, squeeze the clip and remove the frame.
      Fig 22: Squeezing Front Door Outside Handle Frame Sub-Assembly (LH) Clip
      G04224670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Remove the frame through the service hole.

      NOTE: Be sure to remove the outside handle frame together with the clips, as the clips will be damaged if they remain attached to the door panel.
    3. Remove the lock control rod.
  22. REMOVE FRONT DOOR OUTSIDE HANDLE PAD FRONT 
    1. Detach the 2 claws and remove the pad.
      Fig 23: Removing Front Door Outside Handle Pad Front
      G04224671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR 
    1. Detach the 2 claws and remove the pad.
      Fig 24: Removing Front Door Outside Handle Pad Rear
      G04224672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR CHECK ASSEMBLY LH 
    1. Remove the bolt, 2 nuts and the door check.

      HINT:

      Remove the check through the service hole.

      Fig 25: Removing Front Door Check Assembly LH
      G04224673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a clip remover, remove the 2 clips indicated by the 2 arrow marks in the illustration.
    2. Using a clip remover, detach the 17 clips and remove the weatherstrip.

    HINT:

    If clips are damaged during removal, replace them.

    Fig 26: Removing Front Door Weatherstrip LH
    G04224674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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