FRONT DOOR DISASSEMBLY

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

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

  • The procedure listed below is for the LH side.


  1. PRECAUTION (w/ Power Window)

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (w/ Power Window)

    Note

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

  3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (w/ Power Window)


    1. A01E2JQE01
      Text in Illustration
      *A for Double Cab
      *B for Single Cab, for Extra Cab

      Using a moulding remover, detach the 2 clips.

    2. Disconnect the 4 claws and remove the power window regulator master switch assembly with front door armrest base panel.

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


    1. A01E0ZI

      Using a moulding remover, detach the 2 clips.

    2. Disconnect the 4 claws and remove the power window regulator switch assembly with front door armrest base panel.

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


    1. A01E2OFE01
      Text in Illustration
      *1 Protective Tape

      Insert a clip remover between the plate and trim board.

      Tech Tips

      Tape the clip remover tip before use.

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

  6. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. A01E1I8E01
      Text in Illustration
      *A w/o Front No. 2 Speaker
      *B w/ Front No. 2 Speaker

      Detach the 2 clips and remove the front door lower frame bracket garnish.

  7. REMOVE DOOR PULL HANDLE


    1. A01E1G4

      Remove the screw and door pull handle.

  8. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. A01E14HE01
      Text in Illustration
      *1 Clip
      *2 Screw

      for Double Cab:


      1. Remove the clip and screw.

      2. Detach the 8 clips and remove the front door trim board.

    2. A01E23WE01
      Text in Illustration
      *1 Clip
      *2 Screw

      for Single Cab, for Extra Cab:


      1. Remove the clip and screw.

      2. Detach the 9 clips and remove the front door trim board.

  9. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. A01DZ4R

      for Double Cab:


      1. Raise the 7 claws of the front door inner glass weatherstrip as shown in the illustration, and then remove the front door inner glass weatherstrip from the front door trim board.

    2. A01E14C

      for Single Cab, for Extra Cab:


      1. Raise the 8 claws of the front door inner glass weatherstrip as shown in the illustration, and then remove the front door inner glass weatherstrip from the front door trim board.

  10. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY


    1. A01DVJGE01

      Disconnect the connector.

    2. Put a 5 mm (0.197 in.) drill bit into a drill.

    3. Wind tape around the drill bit approximately 5 mm (0.197 in.) from the tip of the drill as shown in the illustration.

      Note

      Tape the 4 mm (0.157 in.) drill bit to prevent the drill bit from going to deep.

      Standard
      Area Specified Condition
      A 5 mm (0.197 in.)

    4. Lightly press the drill against the 3 rivets, drill off the flanges of the 3 rivets and remove the front No. 1 speaker assembly.

      CAUTION:

      Be careful of the drilled rivet as it may become hot.

      Note


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

      • Do not pry the rivet with the drill because this may cause damage to the installation holes of the rivet or the drill bit.

    5. Continue drilling and push out the remaining rivet fragments.

    6. Using a vacuum cleaner, remove the rivet fragments and shavings from the inside of the door.

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


    1. A01DY72

      Disconnect the connector.

    2. Remove the screw and speaker.

  12. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH

    A01E2DQ

    1. w/ Power Mirror Control System:

      Disconnect the mirror connector.

    2. Remove the 3 nuts.

    3. Push down the claw and remove the outer rear view mirror assembly LH.

  13. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. A01DZZVE01

      Detach the claw and 2 guides as indicated by the arrows in the order shown in the illustration.

    2. A01DYGF

      Disconnect the front door inside locking cable and front door lock remote control cable and remove the front door inside handle.

  14. REMOVE FRONT DOOR NO. 1 TRIM BRACKET


    1. A01E188

      Remove the 2 screws and front door No. 1 trim bracket.

  15. REMOVE FRONT DOOR SERVICE HOLE COVER LH


    1. A01DWGI

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

      Tech Tips

      Remove any remaining butyl tape from the front door panel.

  16. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. w/ Power Window:


      1. Temporarily install the power window regulator master switch assembly with front door armrest base panel.

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

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

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

        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 with front door armrest base panel.

    2. w/o Power Window:


      1. Temporarily install the door window regulator handle.

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

      3. Remove the door window regulator handle.

    3. A01E2D0

      Remove the 2 bolts.

      Note

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

    4. A01DZ2AE01

      Remove the front door glass as indicated by the arrows in the order shown in the illustration.

      Note

      Do not damage the front door glass.

  17. REMOVE FRONT DOOR OUTER GLASS WEATHERSTRIP ASSEMBLY LH


    1. A01DVS6E01
      Text in Illustration
      *A for Double Cab
      *B for Single Cab, for Extra Cab
      *1 Protective Tape

      Put protective tape around the front door outer glass weatherstrip.

    2. Detach the 5 claws and remove the front door outer glass weatherstrip.

  18. REMOVE FRONT DOOR GLASS RUN LH


    1. A01DW1O

      Remove the front door glass run.

  19. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. w/ Power Window:


      1. A01DXP3E01
        Text in Illustration
        *1 Temporary Bolt

        Disconnect the connector.

      2. Loosen the temporary bolt.

        Note

        Do not remove the temporary bolt. If the temporary bolt is removed, the front door power window regulator may fall and become damaged.

      3. Remove the 5 bolts and front door power window regulator.

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

    2. w/o Power Window:


      1. A01E18ME01
        Text in Illustration
        *1 Temporary Bolt

        Loosen the temporary bolt.

        Note

        Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall and become damaged.

      2. Remove the 4 bolts and front door window regulator.

      3. Remove the temporary bolt from the front door window regulator.

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


    1. A01DWKV

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

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


    1. A01DWGO

      Remove the 2 nuts and front door rear lower frame.

  22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER


    1. A01DXCY

      Remove the hole plug.

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

    3. A01DWVL

      Detach the 2 claws and remove the front door outside handle cover from the door key cylinder.

  23. REMOVE FRONT DOOR LOCK ASSEMBLY LH


    1. A01E338

      w/ Power Door Lock:


      1. Disconnect the connector.

      2. Disconnect the front door inside locking cable and front door lock remote control cable from the clamps.

      3. Using a T30 "TORX" socket wrench, remove the 3 screws and front door lock.

    2. A01DZ12

      w/o Power Door Lock:


      1. Disconnect the front door inside locking cable and front door lock remote control cable from the clamps.

      2. Using a T30 "TORX" socket wrench, remove the 3 screws and front door lock.

  24. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. A01E0EM

      Remove the front door lock remote control cable.

  25. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. A01DV54

      Detach the 3 claws and open the cover.

    2. A01DVBW

      Remove the front door inside locking cable.

  26. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A01E2CS

      Remove the front door outside handle by sliding and pulling it in the direction indicated by the arrow in the illustration.

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


    1. A01DZK2

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

    2. Detach the claw and remove the front door outside handle frame.

  28. REMOVE FRONT DOOR LOCK OPEN ROD LH


    1. A01E1CTE01
      Text in Illustration
      *1 Snap

      Rotate the snap in the direction indicated by the arrow in the illustration to detach the snap from the front door lock open rod.

    2. Remove the front door lock open rod from the front door outside handle frame.

  29. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A01E0E2

      Detach the 2 claws and remove the front door front outside handle pad.

  30. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A01DV1L

      Detach the 2 claws and remove the front door rear outside handle pad.

  31. REMOVE FRONT DOOR PANEL CUSHION


    1. A01E12U

      Remove the 2 front door panel cushions.

  32. REMOVE FRONT DOOR WEATHERSTRIP LH


    1. A01DYRE

      for Double Cab:


      1. Remove the clip.

      2. Detach the 33 clips and remove the front door weatherstrip.

    2. A01E2P9

      for Single Cab, for Extra Cab:


      1. Remove the clip.

      2. Detach the 34 clips and remove the front door weatherstrip.

  33. REMOVE FRONT DOOR CHECK ASSEMBLY LH


    1. A01E22S

      Remove the 3 bolts and front door check.