Section 1023 (Front Door): Disassembly

HINT:

A bolt without a torque specification is shown in the standard bolt table, (see SPECIFIED TORQUE FOR STANDARD BOLTS )

1. REMOVE INSIDE HANDLE BEZEL 
   1. Using a screwdriver, open the screw cap.

      HINT:

      Tape the screwdriver tip before use.

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

   HINT:

   Tape the screwdriver tip before use.

   Fig 1: Removing Inside Handle Bezel

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE POWER WINDOW SWITCH 
   1. Using a screwdriver, remove the power window switch.

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Removing Power Window Switch

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Disconnect the connectors.
3. REMOVE FRONT ARMREST 
   1. Remove the screw.
   2. Using a screwdriver, remove the front armrest as shown in Fig 3 .

   HINT:

   Tape the screwdriver tip before use.

   Fig 3: Removing Front Armrest

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE LOWER FRAME BRACKET GARNISH 

   Remove the lower frame bracket garnish.

   Fig 4: Removing Lower Frame Bracket Garnish

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE DOOR TRIM 
   1. Using a screwdriver, remove the courtesy light, then disconnect the connector.

      HINT:

      Tape the screwdriver tip before use.

   2. Using a screwdriver, disengage the clips, then pull the trim upward to remove it.

   HINT:

   Tape the screwdriver tip before use.

   Fig 5: Removing Door Trim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT NO.2 SPEAKER 
   1. Disconnect the 2 connectors.
   2. Remove the 2 bolts and front No.2 speaker.
   Fig 6: Removing Front No. 2 Speaker

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE OUTSIDE REAR VIEW MIRROR 
   1. Disconnect the connector.
   2. Remove the bolt and outside rear view mirror.
8. REMOVE FRONT NO.1 SPEAKER 
   1. Disconnect the connector.
   2. Using a drill of less than PHY 4 mm (0.16 in.), drill out the rivet heads and remove the speaker.
      Fig 7: Removing Speaker By Drilling Out Rivet Heads

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   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. 
   4. Even if a 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.
9. REMOVE INSIDE HANDLE 

   Remove the screw and inside handle, disconnect the 2 cables from the inside handle.

   Fig 8: Removing Inside Handle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE SERVICE HOLE COVER 
    1. Remove the 2 screws and door trim bracket.
    2. Remove the service hole cover.
    Fig 9: Removing Service Hole Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE FRONT DOOR INSIDE PANEL PLATE 

    Remove the 2 screws and front door inside panel plate.

12. REMOVE NO.2 SERVICE HOLE COVER 

    Remove the 2 screws and No.2 service hole cover.

    Fig 10: Removing No.2 Service Hole Cover

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE FRONT DOOR BELT MOLDING 
    1. Remove a screw.
    2. Apply protective tape to the outer surface as shown in Fig 11 , to keep the surface from being scratched.
    3. Using a molding remover, remove the front door belt molding as shown in Fig 11 .
    Fig 11: Removing Front Door Belt Molding

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE DOOR GLASS 

    HINT:

    Insert a shop rag inside the door panel to prevent scratching the glass.

    1. Open the door glass until the bolts appear in the service hole.
    2. Remove the 2 bolts and door glass.
    Fig 12: Removing Door Glass

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the door glass. 

    HINT:

    Pull the glass upward to remove it.

15. REMOVE WINDOW REGULATOR 
    1. Disconnect the connector and disengage the clamps.
    2. Remove the 6 bolts and window regulator.
    Fig 13: Removing Window Regulator

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE WINDOW REGULATOR MOTOR 
    1. Place matchmarks on the window regulator motor bracket and regulator gear.
    2. Remove the 3 screws and motor.
17. REMOVE DOOR GLASS RUN 
18. REMOVE REAR LOWER FRAME 

    Remove the bolt and rear lower frame.

19. REMOVE DOOR LOCK 
    1. Disconnect the 2 links from the outside handle and key cylinder.
    2. Remove the bolt and 2 screws.
    3. Using a torx socket wrench, remove the 3 torx screws and door lock.

       Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool) 

       Fig 14: Removing Door Lock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the connector.

    HINT:

    Remove the door lock through the service hole.

20. REMOVE OUTSIDE HANDLE AND KEY CYLINDER 
    1. Remove the screw and hole cover.
    2. Remove the 2 bolts and outside handle with the key cylinder.
       Fig 15: Removing Outside Handle & Key Cylinder

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the retainer from the outside handle.
    4. Remove the bolt, key cylinder and protector from the outside handle.
21. REMOVE CUSHIONS