FRONT DOOR (for TMMK Made) DISASSEMBLY

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B000JHU

      Using a moulding remover, disengage the 3 claws to remove the front door inside handle bezel plug as shown in the illustration.

  4. REMOVE FRONT DOOR FRONT LOWER FRAME UPPER COVER


    1. B000JC8

      Disengage the 2 claws and 2 guides to remove the front door front lower frame upper cover.

  5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)


    1. B000MJ9

      Using a moulding remover, disengage the 2 clips, 6 claws and 3 guides.

    2. Disconnect each connector to remove the power window regulator master switch assembly with front door armrest base panel.

  6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)


    1. B000IX3

      Using a moulding remover, disengage the 2 clips, 6 claws and 3 guides.

    2. Disconnect each connector to remove the power window regulator switch assembly with front door armrest base panel.

  7. REMOVE FRONT ARMREST ASSEMBLY


    1. B000N26

      Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides to remove the front armrest assembly.

  8. REMOVE COURTESY LIGHT ASSEMBLY


    1. B000NPFE01
      Text in Illustration
      *A for LH Side
      *B for RH Side
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, disengage the claw.

    2. Disconnect the connector and remove the courtesy light assembly.

  9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B000KMQE01
      Text in Illustration
      *a Protective Tape

      Apply protective tape to the front door panel.

    2. B000LET

      Remove the 3 screws.

    3. Using a clip remover, disengage the 10 clips.

    4. B000LEFE01
      Text in Illustration
      *1 Front Door Inner Glass Weatherstrip
      *a Reference Boss

      Pull out the front door trim board sub-assembly as shown in the illustration.

    5. Disengage the reference boss from the front door panel.

    6. Raise the front door trim board sub-assembly to remove the front door trim board sub-assembly together with the front door inner glass weatherstrip.

    7. B000M72

      Disengage the clamp.

    8. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly as shown in the illustration.

  10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B000I1U

      Disengage the 2 claws and guide to remove the front door inside handle sub-assembly.

  11. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B000H3BE01
      Text in Illustration
      *a Screwdriver

      Using a screwdriver, disengage the 4 claws and remove the front door inner glass weatherstrip from the front door trim board sub-assembly as shown in the illustration.

  12. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B000HGE

      Disengage the 3 clips to remove the front door lower frame bracket garnish.

  13. REMOVE DOOR SIDE AIRBAG SENSOR


    1. Check that the engine switch is off.

    2. Check that the cable is disconnected from the negative (-) battery terminal.

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

    3. Disconnect the connector from the door side airbag sensor.

      Note

      When disconnecting any airbag connector, take care not to damage the airbag wire harness.


      1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

        B000H9EE12
        Text in Illustration
        *1 White Housing Lock *2 Yellow CPA
        *a Connector Lock is Released - -

      2. Push down the white housing lock again and disconnect the connector.

        Note

        Do not push down the part (A) shown in the illustration when disconnecting.

    4. B000KCV

      Remove the bolt and door side airbag sensor from the front door panel.

      Note

      Loosen the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

    5. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

      B000MUCE01
      Text in Illustration
      *a Incorrect *b Correct

  14. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

    Note

    Do not touch the speaker cone.


    1. B000I5O

      Disconnect the connector.

    2. Remove the 4 screws.

    3. B000MIX

      Disengage the 2 claws and remove the front No. 1 speaker assembly.

  15. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY


    1. B000KZT

      Remove the clip.

    2. B000HRB

      Disconnect the connector.

    3. Remove the 3 bolts.

    4. Disengage the claw.

    5. B000K23

      Disengage the clip to remove the outer rear view mirror assembly.

  16. REMOVE FRONT DOOR SERVICE HOLE COVER


    1. B000K3E

      Remove the bolt.

    2. Disconnect each connector.

    3. Disengage the 5 clamps.

    4. Pass the front door lock remote control cable assembly, front door inside locking cable assembly and each connector through the front door service hole cover.

    5. Remove the front door service hole cover.

      Tech Tips

      Remove any remaining butyl tape from the front door panel.

  17. REMOVE NO. 1 FRONT DOOR SERVICE HOLE SEAL


    1. B000M0G

      Remove the No. 1 front door service hole seal.

  18. REMOVE NO. 2 FRONT DOOR SERVICE HOLE SEAL


    1. B000ITI

      Remove the No. 2 front door service hole seal.

  19. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY


    1. B000IXO

      Remove the grommet.

    2. Connect the cable to the negative (-) battery terminal.

    3. for Driver Side:


      1. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

      2. Disconnect the power window regulator master switch assembly.

    4. for Front Passenger Side:


      1. Connect the power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

      2. Disconnect the power window regulator switch assembly.

    5. Disconnect the cable from the negative (-) battery terminal.

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

      Note

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

    6. B000KMS

      Remove the 2 bolts.

      Note

      After the bolts are removed, do not allow the front door glass sub-assembly to fall.

    7. B000KWWE02

      Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.

      Note

      Do not damage the front door glass sub-assembly.

  20. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. B000M1NE03
      Text in Illustration
      *a Temporary Bolt

      Loosen the temporary bolt.

      Note

      Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator assembly may fall and cause damage.

    2. Remove the 5 bolts.

    3. Remove the front door window regulator assembly.

    4. Remove the temporary bolt from the front door window regulator assembly.

  21. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY


    1. B000NAJ

      Using a T25 "TORX" socket wrench, remove the 3 screws and front power window regulator motor assembly.

  22. REMOVE NO. 2 FRONT DOOR STIFFENER CUSHION


    1. B000MRNE01
      Text in Illustration
      *a Double-sided Tape

      Remove the 2 bolts.

    2. Disengage the 2 guides and remove the No. 2 front door stiffener cushion.

  23. REMOVE FRONT DOOR GLASS RUN


    1. B000M32

      Remove the front door glass run.

  24. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. B000K02

      Remove the 2 bolts.

    2. Disengage the guide and remove the front door front lower frame sub-assembly as shown in the illustration.

  25. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B000K2W

      Remove the 2 bolts.

    2. Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration.

  26. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)


    1. B000MX5

      Remove the hole plug.

    2. B000JIB

      Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover with lock cylinder assembly.

      Tech Tips

      The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

  27. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)


    1. B000LKT

      Using a screwdriver, disengage the claw and 2 guides, and remove the front door outside handle cover from the lock cylinder assembly as shown in the illustration.

  28. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)


    1. B000HP1

      Remove the hole plug.

    2. B000NFR

      Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.

      Tech Tips

      The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

  29. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B000M4J

      Disengage the 2 claws.

    2. Using a screwdriver, disconnect the connector.

    3. B000HCL

      Remove the front door outside handle assembly as shown in the illustration.

  30. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B000LV7

      Disengage the 3 claws to remove the front door front outside handle pad.

  31. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B000NJ0

      Disengage the 2 claws to remove the front door rear outside handle pad.

  32. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY


    1. B000JAXE01
      Text in Illustration
      *1 Front Door Lock Open Rod

      Using a T30 "TORX" socket wrench, remove the 3 screws.

    2. Slide the front door lock with motor assembly downward to disconnect the front door lock open rod and remove the front door lock with motor assembly and cables as a unit.

    3. When reusing the front door lock with motor assembly:


      1. B000HW4

        Remove the door lock wiring harness seal from the front door lock with motor assembly.

  33. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B000J7D

      Remove the front door lock remote control cable assembly as shown in the illustration.

  34. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B000II5

      Using a screwdriver, disengage the 3 claws.

    2. B000HMH

      Remove the front door inside locking cable assembly as shown in the illustration.

  35. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. B000JIV

      Disconnect the connector.

    2. Disengage the 3 clamps.

    3. B000NP9E01
      Text in Illustration
      *A Outside
      *B Inside
      *1 Door Handle Nut

      Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

    4. Slide the front door outside handle frame sub-assembly to disengage the claw of the front door outside handle frame sub-assembly, and then remove it.

  36. REMOVE FRONT DOOR WIRE


    1. B000NAD

      Disengage the 3 clamps and remove the front door wire.

  37. REMOVE FRONT DOOR LOCK OPEN ROD


    1. B000MINE02

      Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

  38. REMOVE FRONT DOOR CHECK ASSEMBLY


    1. B000K6W

      Remove the 3 bolts and front door check assembly.

  39. REMOVE FRONT DOOR WEATHERSTRIP


    1. B000HR1

      Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.

  40. REMOVE DOOR FRAME GARNISH


    1. B000M2I

      Disengage the clip and remove the door frame garnish.

      Tech Tips

      This garnish needs to be replaced with a new one because the clip will break when removing it.

  41. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP


    1. B000JY5

      Using a clip remover, disengage the 8 clips and remove the front door No. 2 weatherstrip.

  42. REMOVE FRONT DOOR PANEL CUSHION


    1. B000I4K

      Disengage the 2 claws and remove the 2 front door panel cushions.

  43. REMOVE DOOR DUST PROOF SEAL


    1. B000LZQE01
      Text in Illustration
      *A for Front Side
      *B for Rear Side

      Remove the 2 door dust proof seals.

  44. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY


    1. B000JNQ

      Apply protective tape around the front door belt moulding assembly as shown in the illustration.

      Text in Illustration
      B000JL5 Protective Tape
    2. B000KA8E01
      Text in Illustration
      *a Screwdriver
      B000JL5 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, disengage the 5 claws as shown in the illustration and remove the front door belt moulding assembly.

  45. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING

    Tech Tips

    When removing the front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light.

    Heating Temperature
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Front Door Rear Window Frame Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or front door rear window frame moulding excessively.


    1. Using a heat light, heat the front door rear window frame moulding.

    2. B000NL2E01
      Text in Illustration
      *a Caulking Sponge
      B000JL5 Double-sided Tape

      Using a moulding remover, disengage the clip and guide, and separate the double-sided tape to remove the front door rear window frame moulding.

  46. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING


    1. Insert a 4.0 mm (0.157 in.) drill bit into a drill.

    2. B000NAAE01

      Tape the 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

      Standard Measurement
      Area Measurement
      A 5.0 mm (0.197 in.)

      Note

      Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

    3. Lightly press the drill against the rivets to drill off the rivet flanges, and remove the 7 rivets.

      Note


      • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.

      • Prying the rivets with the drill may damage the rivet installation holes or drill bit.

      • Be careful of the drilled rivets, as they may be hot.

    4. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas.

    5. Disengage the claw and guide, and remove the front door upper window frame moulding from the door frame.

  47. REMOVE FRONT DOOR STRIPE


    1. Using a heat light, heat the front door stripe and vehicle body.

      Heating Temperature
      Item Temperature
      Vehicle Body and Front Door Outside Stripe 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. B000M1I

      Pull back on one of the ends of the front door stripe to remove it.

      Tech Tips

      When pulling on the stripe, pull it parallel to the body.

  48. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE


    1. Using a heat light, heat the front door lower outside stripe and vehicle body.

      Heating Temperature
      Item Temperature
      Vehicle Body and Front Door Rear Outside Stripe 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. B000IIU

      Pull back on one of the ends of the front door lower outside stripe to remove it.

      Tech Tips

      When pulling on the stripe, pull it parallel to the body.