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Front Door: Disassembly

  1. w/o Power window: 
    1. 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
    G02896412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    • At the time of reassembly, please refer to the following item.
    • With door window fully closed, install the plate and regulator handle with the snap ring in the position within +/- 15° as shown in the illustration.
      Fig 2: Installing Plate And Regulator Handle
      G02896413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE LOWER FRAME BRACKET GARNISH 

    Using a screwdriver, remove the lower frame bracket garnish.

    HINT:

    Tape the screwdriver tip before use.

    Fig 3: Removing Lower Frame Bracket Garnish
    G02896414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 2 DOOR INSIDE HANDLE BEZEL 

    Using a screwdriver, remove the No. 2 door inside handle bezel.

    HINT:

    Tape the screwdriver tip before use.

    Fig 4: Removing No. 2 Door Inside Handle Bezel
    G02896415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE REMOTE CONTROL MIRROR SWITCH 

    Using a screwdriver, remove the remote control mirror switch, then disconnect the connector.

    HINT:

    Tape the screwdriver tip before use.

    Fig 5: Removing Remote Control Mirror Switch
    G02896416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE DOOR TRIM 
    1. Using a screwdriver, remove the 2 plug hole covers.

      HINT:

      Tape the screwdriver tip before use.

    2. Remove the 6 screws.
    3. Insert a screwdriver between the door panel and door trim to pry the trim out.
      Fig 6: Removing Door Trim
      G02896417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Tape the screwdriver tip before use.

    4. Pull the trim upward to remove it, then disconnect the locking cable and open cable from the door inside handle.

      HINT:

      • At the time of reassembly, please refer to the following items.
      • Check that a ball at the end of the locking cable is pressed. (The cable should be locked.)
      • Turn the locking knob of the inside handle fully to the lock side and install the locking cable.
    5. Remove the screw and door inside handle from the door trim.
    6. Using a screwdriver, remove the front door inner weatherstrip from the door trim.
      Fig 7: Disconnecting Locking Cable
      G02896418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE DOOR SIDE AIRBAG SENSOR 
    NOTE:
    • If the wiring connector of the SRS is disconnected with the ignition switch in ON or ACC position, DTCs will be recorded.
    • Never use SRS parts removed from another vehicle. When replacing parts, replace them with new ones.
    • Never reuse the sensor involved in a collision where the SRS has deployed.
    • Never repair a sensor in order to reuse it.

    Disconnect the connector, then remove the 2 bolts and door side airbag sensor.

    1. Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 
    NOTE:
    • At the time of reassembly, please refer to the following items.
    • Make sure the sensor is installed in the specified torque.
    • If the sensor has been dropped, or there are cracks, dents or any other defects are identified in the case, brackets or connector, replace the sensor. Always replace the set bolts with new ones.
    • The sensor set bolts have been anti-rust treated. When the sensor is removed, always replace the set bolts with new ones.
    • After installation, shake the sensor to check that there is no looseness.
    • The sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If not, a malfunction code may be detected by the diagnostic system.
  7. REMOVE OUTSIDE REAR VIEW MIRROR 
    1. Torque: 8.3 N.m (85 kgf.cm, 74 in..lbf) 
  8. w/ Tweeter speaker: 
    1. REMOVE TWEETER SPEAKER 
  9. REMOVE 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 cables and wire harness through the slits of service hole cover.
  10. REMOVE FRONT DOOR WEATHERSTRIP 
    1. Using a clip remover, remove the 4 clips.

      HINT:

      Tape the screwdriver tip before use.

    2. Using a clip remover, remove the front door weatherstrip.

      HINT:

      Tape the screwdriver tip before use.

      Fig 8: Removing Front Door Weatherstrip
      G02896419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT DOOR BELT MOLDING 
    1. Remove the screw.
    2. Using a molding remover, remove the front door belt molding.
      Fig 9: Removing Front Door Belt Molding
      G02896420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE UPPER WINDOW STOPS 

    Remove the 2 bolts and 2 upper window stops

    1. Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 
      Fig 10: Removing Upper Window Stops
      G02896421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE DOOR GLASS 
    1. Close the door glass until the nuts appear in the service hole.
    2. Remove the 3 nuts.
      1. Torque: 7.8 N.m (80 kgf.cm, 69 in..lbf) 
    3. Take the door glass out of the panel carefully.
    NOTE: Be careful not to drop the door glass.
    Fig 11: Removing Door Glass
    G02896422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    • At the time of reassembly, please refer to the following item.
    • Insert a shop rag inside the panel to prevent the glass from being scratched.
      Fig 12: Inserting Shop Rag Inside Panel
      G02896423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE WINDOW REGULATOR 
    1. Remove the bolt of lower plate
      1. Torque: 4.9 N.m (50 kgf.cm, 43 in..lbf) 
    2. Unlock the snap by pulling the lower plate.
    3. Remove the snap and lower plate from the stud bolt of lower bracket.
    4. Remove the setting nut.
    5. w/ Power window:

      Disconnect the connector.

    6. Remove the 5 nuts and window regulator
      1. Torque: 8.3 N.m (85 kgf.cm, 74 in..lbf) 
  15. w/ Power window: 
    1. If replacing the window regulator: 

    REMOVE WINDOW REGULATOR FROM MOTOR 

    1. Remove the 2 screws and cover plate.
    2. Using needle nose pliers, remove the drum and wire guide from the motor.
    NOTE: Do not use a screwdriver etc. to remove them.
    Fig 13: Removing Window Regulator From Motor
    G02896424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE SPEAKER 
    1. Using a rivet cutter and drill, drill out the rivets and remove the speaker.

      HINT:

      Even if flanges are taken off, continue drilling and push out remaining filaments with the drill.

    2. Disconnect the connector.
    3. Using a vacuum cleaner, remove the drilled rivets and the associated metallic dust from the inside of the door panel.
      Fig 14: Removing Speaker
      G02896425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION: Do not touch the cut rivets and rivet cutter as they will be not.
    NOTE:
    • Do not jiggle the rivet cutter while cutting.
    • Otherwise you may enlarge the rivet hole or damage the rivet cutter.

    HINT:

    Do not drill the door inner hole.

    HINT:

    At the time of reassembly, please refer to the following item. Using an air riveter, strike rivets into the door panel to install the speaker to the door panel.

    Fig 15: Installing Speaker To Door Panel
    G02896426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: At the time of reassembly, please refer to the following item.
    If the rivets are not positioned perpendicular to the assembled surface the mandrel will be bent. If the trigger is pulled in this condition, the air riveter may be also damaged.
    Fig 16: Identifying Rivets Incorrect Condition
    G02896427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE DOOR GLASS FEMALE STABILIZER 

    Remove the screw and door glass female stabilizer

    1. Torque: 4.9 N.m (50 kgf.cm, 43 in..lbf) 
      Fig 17: Removing Door Glass Female Stabilizer
      G02896428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT LOWER FRAME 
    1. Remove the 2 screws.
    2. Disengage the clamp of door wire harness from the front lower frame.
    3. Remove the front lower frame through the service hole.
    4. Remove the door glass run from the lower frame.
      Fig 18: Removing Front Lower Frame
      G02896429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Using a clip remover, remove the clip.
    2. Remove the front door No. 2 weatherstrip.
      Fig 19: Removing Front Door No. 2 Weatherstrip
      G02896430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE DOOR LOCK 
    1. Disconnect the 2 links from the outside handle and key cylinder.
    2. w/o Power door lock:

      Remove the nut and 3 screws

      1. Torque: 
      2. Nut: 5.4 N.m (55 kgf.cm, 48 in..lbf) 
      3. Screw: 4.9 N.m (50 kgf.cm, 43 in..lbf) 
    3. w/ Power door lock:

      Disconnect the connector and remove the bolt, nut and 3 screws

      1. Torque: 
      2. Nut: 5.4 N.m (55 kgf.cm, 48 in..lbf) 
      3. Bolt, Screw: 4.9 N.m (50 kgf.cm, 43 in..lbf) 

      HINT:

      • At the time of reassembly, please refer to the following item.
      • Apply adhesive to 3 screws.
      1. Part No. 08833-00070, THREE BOND 1324 or equivalent 
        Fig 20: Removing Door Lock
        G02896431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the door lock through the service hole.
    5. Remove the door lock link clamp.

    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.
  21. REMOVE OUTSIDE HANDLE 
    1. Remove the 2 bolts and outside handle with key cylinder
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 
    2. Remove the bolt and key cylinder from the outside handle.
      1. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 
        Fig 21: Applying MP Grease To Sliding And Rotating Parts Of Door Lock
        G02896432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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