Front Door: Disassembly

NOTE:

Tape the screwdriver tip before use.

Fig 1: Removing Inside Handle Bezel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, open the screw cap.
2. Remove the screw.
NOTE:

Tape the screwdriver tip before use.

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

1. Remove the screw.
   Fig 2: Removing Power Window Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:

Tape the screwdriver tip before use.

2. Using a screwdriver, remove the power window switch.
3. Disconnect the connectors.

NOTE:

Tape the screwdriver tip before use.

Fig 3: Removing Lower Frame Bracket Garnish
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the lower frame bracket garnish.
2. Remove the front flame cover.

1. Remove the clip.
CAUTION: Be careful not damage the door panel and trim.
Tape the screwdriver tip before use.
2. Insert a screwdriver between the door panel and door trim to pry the trim out.
3. Pull the door trim upward to remove it.
   Fig 4: Removing Door Trim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the screw and inside handle, disconnect the 2 cables from the inside handle as shown in Fig 5.

Fig 5: Removing Inside Handle

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1. Remove the 2 screws and door trim No. 1 bracket.
   Fig 6: Removing Door Trim Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 grommets.
CAUTION: Do not tear the cover.
NOTE:
• 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.
3. Remove the service hole cover.

1. Disconnect the connector.
2. Using a drill of less then o/ 4 mm (0.16 in), drill out the rivet heads and remove the speaker.
3. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
   CAUTION:

   • 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 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.

NOTE:

At the time of reassembly, please refer to the following item. Using an air riveter and nose piece No.1, strike rivets into the door panel to install the speaker to the door panel.

Fig 8: Installing Speaker

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CAUTION: At the time of reassembly, please refer to the following item.
If the rivet is not positioned perpendicularly it will bend the mandrel. When the trigger is then pulled, it may damage the air riveter.

Fig 9: Identifying Mandrel

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1. Disconnect the connector.
2. Remove the 3 nuts and outside view mirror.

   Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 

Using a scraper, remove the door belt moulding.

1. Remove the 3 bolts and reinforce inside extension.
   Fig 11: Removing Bolts And Reinforce Inside Extension

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Open the door glass until the door belts appear in the service hole.
CAUTION: Be careful not to drop the door glass.
3. Remove the 2 bolts.
4. Pull the door glass upward to remove it.

Remove the 2 nuts, plate and lower frame.

Fig 12: Removing Lower Frame

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1. Disconnect the connector.
2. Remove the 2 bolts from the window regulator.
   Fig 13: Removing Window Regulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

3. Remove the 4 bolts and window regulator.

   Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf) 

1. Disconnect the control cable from the clamp.
2. Disconnect the 2 links from the outside handle and key cylinder.
3. Disconnect the connector.
4. Remove the bolt.
   Fig 14: Removing Door Lock

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

5. Remove the 3 screws and door lock.

   Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

1. Remove the 2 bolts and outside handle.
   Fig 15: Removing Outside Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Remove the key cylinder from the handle.