FRONT DOOR DISASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the LH side.

  • Use the same procedure for RHD and LHD vehicles.

  • The procedures listed below are for LHD vehicles.

  • Fully open the front door glass sub-assembly LH before proceeding with work.

PROCEDURE


  1. PRECAUTION

    CAUTION:

    w/ Curtain Shield Airbag:

    Be sure to read Precaution thoroughly before servicing.

    B0069A2

    Click here

    Note

    After turning the ignition 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 notice before proceeding with work.

    Click here

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    w/ Curtain Shield Airbag:

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

    • If the airbag deploys for any reason, it may cause a serious accident.

    B00693Q

    Note

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

    Click here

  3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. Detach the clip and claw and remove the front door lower frame bracket garnish LH.

      B0024VPC01
      *A w/ Front No. 2 Speaker *B w/o Front No. 2 Speaker

  4. REMOVE FRONT ARMREST ASSEMBLY LH


    1. B0028MPC01
      B0068AS Place Hands Here
      B0068HS Order of Removal
      B0069FO Remove in this Direction

      for Single Cab, Smart Cab:

      Detach the clip and claw and remove the front armrest assembly LH as shown in the illustration.

    2. B0027DPC01
      B0068AS Place Hands Here
      B0068HS Order of Removal
      B0069FO Remove in this Direction

      for Double Cab:

      Detach the clip and claw and remove the front armrest assembly LH as shown in the illustration.

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


    1. B0028DJC01
      *A for Single Cab, Smart Cab
      *B for Double Cab
      B0069FO Remove in this Direction

      Detach the clip and claw.

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

  6. REMOVE OUTER MIRROR SWITCH ASSEMBLY (for Driver Side, w/ Power Window)

    Click here

  7. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side, w/ Power Window)


    1. for Models with Jam Protection Function on Driver Door Window Only:

      Click here

    2. except Models with Jam Protection Function on Driver Door Window Only:

      Click here

  8. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side, w/ Power Window)


    1. B0028SGC01
      B0069FO Remove in this Direction

      Detach the clip and claw.

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

  9. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side, w/ Power Window)

    Click here

  10. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)


    1. B0028KYC01
      B00692L Protective Tape
      B0069FO Remove in this Direction

      Insert a clip remover between the plate and front door trim board.

      Tech Tips

      Tape the clip remover tip before use.

    2. Turn the handle clockwise to remove the snap ring, front door window regulator handle assembly and plate.

  11. REMOVE FRONT DOOR TRIM REFLECTOR LH (w/ Reflex Reflector Assembly)


    1. B002876C03
      *A for LH side
      *B for RH side
      B00692L Protective Tape
      B0069FO Remove in this Direction (1)
      B0068NX Remove in this Direction (2)

      Put protective tape around the reflex reflector.

    2. Using a thin-bladed screwdriver, detach the claw and guide.

      Tech Tips

      Tape the thin-bladed screwdriver tip before use.

    3. Remove the front door trim reflector LH.

  12. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


    1. B0026AP

      Using moulding remover A, detach the claw and remove the front door inside handle bezel plug LH as shown in the illustration.

  13. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B0024NX

      Remove the 3 screws.

    2. Detach the clip as shown in the illustration.

      B0026ZHC01
      *A for Single Cab, Smart Cab *B for Double Cab
      B0068AS Place Hands Here - -
      B0068HS Order of Removal (1) B006964 Order of Removal (2)
      B0069FO Remove in this Direction - -
    3. B00288IC01
      B0069FO Remove in this Direction

      Detach the guide and remove the front door trim board sub-assembly LH as shown in the illustration.

    4. B0027PRC01
      *1 Front Door Inside Looking Cable Assembly LH
      *2 Front Door Lock Remote Control Cable Assembly LH
      B0069FO Remove in this Direction

      Detach the clamp and disconnect the front door lock remote control cable assembly LH and front door inside looking cable assembly LH as shown in the illustration.

  14. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. B00294IC01
      B0069FO Remove in this Direction

      Detach the claw and guide and remove the front door inside handle sub-assembly LH from the front door trim board sub-assembly LH.

  15. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. Raise the claw of the front door inner glass weatherstrip LH as shown in the illustration, and then remove the front door inner glass weatherstrip LH from the front door trim board sub-assembly LH.

      B0025QEC01
      *A for Single Cab, Smart Cab *B for Double Cab

  16. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  17. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (w/ Front No. 2 Speaker)

    Click here

  18. REMOVE DOOR SIDE AIR BAG SENSOR LH (w/ Curtain Shield Airbag)

    Click here

  19. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  20. REMOVE FRONT DOOR SERVICE HOLE COVER LH


    1. B0028RVC01
      B0024II Butyl Tape

      w/ Curtain Shield Airbag:

      Remove the ground bolt and disconnect the ground wire.

    2. w/ Power Mirror Control System:

      Detach the clamp.

    3. Detach the clamp.

    4. Pull out the front door lock remote control cable assembly LH, front door inside locking cable assembly LH and wire harness from the front door service hole cover LH, and then remove the front door service hole cover LH.

      Note

      Remove any remaining butyl tape from the front door panel.

  21. REMOVE SCREW GROMMET


    1. B0027E8

      Using a clip remover, detach the claw and remove the 2 screw grommets.

  22. REMOVE FRONT DOOR GLASS RUN LH


    1. B0026C0

      for Single Cab, Smart Cab:

      Detach the guide and remove the front door glass run LH.

    2. B0026C0

      for Double Cab:

      Detach the guide and remove the front door glass run LH.

  23. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. w/ Power Window:


      1. Temporarily install the power window regulator master switch assembly.

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

      3. Move the front door window regulator sub-assembly LH so that the front door glass sub-assembly LH bolts can be seen.

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

        CAUTION:

        w/ Curtain Shield Airbag:

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

        • If the airbag deploys for any reason, it may cause a serious accident.

        B00693Q

        Note

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

        Click here

      5. Remove the power window regulator master switch assembly.

    2. w/o Power Window:


      1. Temporarily install the front door window regulator handle assembly.

      2. Move the front door glass sub-assembly LH so that the front door glass sub-assembly LH bolts can be seen.

      3. Remove the front door window regulator handle assembly.

    3. B0028ZY

      Remove the 2 bolts.

    4. B0025HTC01
      B0069FO Remove in this Direction (1)
      B0068NX Remove in this Direction (2)

      Remove the front door glass sub-assembly LH as shown in the illustration.

      Note

      Do not damage the front door glass sub-assembly LH.

  24. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH


    1. B00274S

      Remove the bolt.

    2. Detach the guide and remove the front door rear lower frame sub-assembly LH.

  25. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. w/ Power Window:

      Disconnect the connector.

    2. Loosen the temporarily bolt.

      Note

      Do not remove the temporarily bolt. If the temporarily bolt is removed, the front door window regulator sub-assembly LH may fall and become damaged.

    3. w/ Power Window:

      Remove the 5 bolts and front door window regulator sub-assembly LH.

    4. w/o Power Window:

      Remove the 4 bolts and front door window regulator sub-assembly LH.

      B0025HOC01
      *A w/ Power Window *B w/o Power Window
      B0068HS Bolt B006964 Connector
      B0069AV Temporarily Bolt - -

    5. Remove the temporarily bolt from the front door window regulator sub-assembly LH.

  26. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (w/ Power Window)

    Click here

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


    1. B0024PBC01
      *1 Hole Plug
      B0069FO Remove in this Direction

      Remove the hole plug.

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

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


    1. B0024KZC01
      B00692L Protective Tape
      B0069FO Remove in this Direction

      Using a thin-bladed screwdriver, detach the claw and guide and remove the front door outside handle cover from the lock cylinder assembly as shown in the illustration.

      Tech Tips

      Tape the thin-bladed screwdriver tip before use.

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


    1. B00280FC01
      *1 Hole Plug
      B0069FO Remove in this Direction

      Remove the hole plug.

    2. Using a T30 "TORX" socket wrench, loosen the screw.

    3. Detach the claw and remove the front door outside handle cover as shown in the illustration.

  30. REMOVE FRONT DOOR LOCK ASSEMBLY LH

    Click here

  31. REMOVE FRONT DOOR LOCK COVER SUB-ASSEMBLY LH (w/o Double Locking System)

    Click here

  32. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

    Click here

  33. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

    Click here

  34. REMOVE DOOR LOCK WIRING HARNESS SEAL

    Click here

  35. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B0024K0C01
      B00692L Protective Tape
      B0069FO Remove in this Direction

      Using a thin-bladed screwdriver, detach the claw and open the connector cover as shown in the illustration.

      Tech Tips

      Tape the thin-bladed screwdriver tip before use.

    2. B002889C01
      B00692L Protective Tape

      Using a thin-bladed screwdriver, detach the claw and disconnect the connector and connector cover.

      Tech Tips

      Tape the thin-bladed screwdriver tip before use.

    3. B00287WC01
      B0069FO Remove in this Direction

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

  36. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B0026RRC01
      B0069FO Remove in this Direction

      Detach the claw and remove the front door front outside handle pad.

  37. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B0024ZGC01
      B0069FO Remove in this Direction

      Detach the claw and remove the front door rear outside handle pad.

  38. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH


    1. B0026MGC01
      *a Grommet
      *b Guide
      B0069FO Remove in this Direction

      Using a T30 "TORX" socket wrench, loosen the screw.

    2. Detach the grommet and guide and remove the front door outside handle frame sub-assembly LH together with the wire harness.

    3. B002778C01
      *a Clamp
      *b Guide

      Detach the clamp and guide, disconnect the wire harness and remove the front door outside handle frame sub-assembly LH.

  39. REMOVE FRONT DOOR LOCK OPEN ROD LH


    1. B0028MQC01
      B0069FO Remove in this Direction

      Detach the snap and remove the front door lock open rod LH from the front door outside handle frame sub-assembly LH as shown in the illustration.

  40. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH

    Click here

  41. REMOVE FRONT DOOR DUST PROOF SEAL


    1. B00275G

      Detach the claw and remove the 3 front door dust proof seals.

  42. REMOVE FRONT DOOR PANEL CUSHION


    1. B0025OW

      Detach the claw and remove the 2 front door panel cushions.

  43. REMOVE FRONT DOOR CHECK ASSEMBLY LH


    1. B0027XDC01
      B0068HS Bolt (A)
      B006964 Bolt (B)

      Remove the 2 bolts (A), bolt (B) and front door check assembly LH.

  44. REMOVE FRONT DOOR WEATHERSTRIP LH


    1. B0027KL

      for Single Cab:

      Using a clip remover, detach the clip and remove the front door weatherstrip LH.

    2. B0026ZW

      for Smart Cab:

      Using a clip remover, detach the clip and remove the double-sided tape front door weatherstrip LH.

      Note

      Remove any remaining double-sided tape from the front door panel LH.

    3. B0026NC

      for Double Cab:

      Using a clip remover, detach the clip and remove the front door weatherstrip LH.

  45. REMOVE NO. 1 BLACK OUT TAPE LH (w/ Black Out Tape)

    Click here