Front Door: Disassembly

HINT:

Tape the screwdriver tip before using it to pry the parts.

1. REMOVE DOOR INSIDE HANDLE BEZEL 

   Using a screwdriver, remove the screw and door inside handle bezel as shown in the illustration.

   Fig 1: Removing Screw And Door Inside Handle Bezel

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE DOOR TRIM 
   1. Using a screwdriver, remove the plug hole cover and screw.
   2. Using a screwdriver, remove the door armrest cover, assist grip cover and 2 screws.
   3. Using a screwdriver, pry the door trim (7 clips) and remove it upward.
   4. Remove the screw and door assist grip.
   5. w/ Tweeter speaker:

      Using a screwdriver, remove the tweeter speaker cover.

      Fig 2: Removing Screw And Door Assist Grip

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Slide the door inside handle and remove it.
   7. Disconnect the 2 cables 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.
   8. Using a screwdriver, remove the front door inner weatherstrip from the door trim.
3. w/ Tweeter speaker: REMOVE TWEETER SPEAKER 
   Fig 3: Identifying Cables From Door Inside Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE SERVICE HOLE COVER 

   Remove the 3 clips and service hole cover.

   NOTE: Do not tear the cover.

   HINT:

   At the time of reassembly, pull out the 2 cables and wire harness through the slits of the service hole cover.

   Fig 4: Removing Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE FRONT DOOR WEATHERSTRIP 
   1. Using a clip remover, remove the 6 clips.
   2. Using a screwdriver, remove the front door weatherstrip.
   Fig 5: Identifying Door Weatherstrip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT DOOR BELT MOULDING 
   1. Using a clip remover, remove the clip.
   2. Using a moulding remover, remove the front door belt moulding.

   HINT:

   Apply a protective tape to the outer surface to keep the surface from being scratched.

   Fig 6: Identifying Protective Tape And Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE UPPER WINDOW STOPS 

   Remove the 2 bolts and 2 upper window stops.

   Torque: 13 N-m (130 kgf.cm, 10 ft.lbf) 

   Fig 7: Identifying Bolts And Upper Window Stops

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE DOOR GLASS 
   1. Close the door glass until the nuts appear in the service hole.
   2. Remove the nut and 2 bolts.

      Torque: 

      8 N.m (80 kgf.cm, 70 in.lbf) for nut 

      7 N.m (70 kgf.cm, 60 in.lbf) for bolt 

   3. Take the door glass out of the panel carefully.
   NOTE: Be careful not to drop the door glass.

   HINT:

   At the time of reassembly, insert a shop rag inside the panel to prevent the glass from being scratched.

   Fig 8: Locating Door Glass

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE WINDOW REGULATOR 
   1. Remove the bolt from the lower plate.

      Torque: 5 N.m (50 kgf.cm, 44 in.lbf) 

   2. Unlock the snap by pulling the lower plate.
   3. Remove the snap and lower plate from the stud bolt of the lower bracket.
   4. Remove the setting nut.
   5. Disconnect the connector.
   6. Remove the 2 nuts and window regulator.

      Torque: 5.5 N.m (55 kgf.cm, 48 in.lbf) 

   Fig 9: Removing Bolt From Lower Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. If replacing 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.
11. REMOVE SPEAKER 
    1. Remove the 3 bolts and speaker.
    2. Disconnect the connector.
    Fig 10: Removing Drum And Wire Guide From Motor Using Needle Nose Pliers

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. REMOVE DOOR GLASS FEMALE STABILIZER 

    Remove the screw and door glass female stabilizer.

    Torque: 13 N.m (130 kgf.cm, 10 ft.lbf) 

    Fig 11: Removing Screw

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE FRONT LOWER FRAME 
    1. Remove the bolt and nut.
    2. Disengage the clamp of the door wire harness from the front lower frame.
    3. Remove the front lower frame.
    4. Remove the door glass run from the lower frame.
    Fig 12: Identifying Front Lower Frame

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE DOOR LOCK 
    1. Disconnect the 2 links from the outside handle and key cylinder.
    2. Disconnect the connector and remove the 3 screws.

       Torque: 5 N.m (50 kgf.cm, 44 in.-lbf) 

       HINT:

       At the time of reassembly, apply adhesive to the 3 screws.

       Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

    3. Remove the door lock.
    4. Remove the door lock link clamp.
    Fig 13: Removing Links From Outside Handle And Key Cylinder

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    At the time of reassembly, apply MP grease to the sliding and rotating parts of the door lock.

15. REMOVE OUTER MIRROR 
    1. Remove the 2 nuts.
    2. Remove the connector and mirror.
16. REMOVE OUTSIDE HANDLE 
    1. Remove the 2 bolts and outside handle with key cylinder.

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

    2. Remove the bolt and key cylinder from the outside handle.

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

    Fig 14: Identifying Bolts And Outside Handle With Key Cylinder

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002