Operation CHARM: Car repair manuals for everyone.
Home >> Scion >> 2011 >> tC L4-2.5L (2AR-FE) >> Repair and Diagnosis >> Body and Frame >> Doors, Hood and Trunk >> Doors >> Front Door >> Service and Repair >> Disassembly

Disassembly





DOOR / HATCH: FRONT DOOR: DISASSEMBLY

HINT
* Use the same procedure for the RH and LH sides.
* The procedure listed below is for the LH side.

1. 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.

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH

(a) Detach the 2 clips and remove the garnish.





3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH

(a) Using moulding remover A, detach the 3 claws and remove the inside handle bezel plug.





4. REMOVE DOOR ASSIST GRIP COVER LH

(a) Using moulding remover A, detach the 7 claws and remove the door assist grip cover.





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

(a) Using moulding remover A, detach the clip and 9 claws and remove the power window regulator master switch assembly with front door armrest base panel.





(b) Disconnect the connector.

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

(a) Use the same procedure described for the driver side.

7. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) Removal

8. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) Removal

9. REMOVE DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) Removal

10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Remove the 3 screws.





(b) Using a clip remover, detach the 11 clips.

(c) Pull out the front door trim board sub-assembly in the direction indicated by the arrow in the illustration.

(d) Pull out the front door trim board in the direction indicated by the arrow in the illustration to detach the 6 claws of the front inner door glass weatherstrip and remove the reference boss together with the trim board.





Text in Illustration





(e) Disconnect the front No. 3 speaker connector.

(f) Disconnect the 2 cables from the inside handle.





11. REMOVE FRONT NO. 3 SPEAKER ASSEMBLY Removal

12. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY Removal

13. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY Removal

14. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP LH

(a) Remove the front door inner glass weatherstrip.





15. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH

16. REMOVE FRONT DOOR BELT MOULDING LH

17. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH

(a) Detach the 2 claws and remove the inside handle sub-assembly from the door trim board.





18. REMOVE DOOR SIDE AIRBAG SENSOR LH Removal

19. REMOVE FRONT DOOR SERVICE HOLE COVER LH

(a) Disconnect the door lock connector.





(b) Remove the bolt.

(c) Remove the service hole cover.

NOTICE:
Remove any remaining butyl tape from the door.

20. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH

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

(b) 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 cable from the negative (-) battery terminal and power window regulator master switch assembly.

(c) 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 cable from the negative (-) battery terminal and power window regulator switch assembly.

(d) Remove the 2 bolts.





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

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





NOTICE:
Do not damage the door glass.

21. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

(a) Disconnect the regulator motor connector.





(b) Loosen the temporary bolt.

Text in Illustration





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

(c) Remove the 5 bolts.

(d) Remove the front door window regulator sub-assembly.

(e) Remove the temporary bolt from the front door window regulator sub-assembly.

22. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH Removal

23. REMOVE FRONT DOOR GLASS RUN LH

(a) Detach the guide and remove the front door glass run.





24. REMOVE DOOR FRAME GARNISH LH

(a) Detach the clip and remove the door frame garnish.





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

(a) Remove the bolt.





NOTICE:
Be careful when removing the bolt as the frame may fall and become damaged.

(b) Detach the claw and remove the front door rear lower frame.

HINT
Remove the frame through the service hole.

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

(a) Remove the hole plug.





Text in Illustration





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

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

(c) Using a screwdriver, detach the 3 claws and remove the front door outside handle cover.





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

(a) Remove the hole plug.





Text in Illustration





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

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

28. REMOVE FRONT DOOR LOCK ASSEMBLY LH Removal

29. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Remove the front door lock remote control cable assembly.





30. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Using a screwdriver, detach the 3 claws.





HINT
Tape the screwdriver tip before use.

(b) Remove the front door inside locking cable assembly.





31. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) w/ Smart Key System:

(1) Disconnect the 2 claws of the connector cover as shown in the illustration.





Text in Illustration





(2) Push the claw of the connector and disconnect the front door wire as shown in the illustration.





Text in Illustration





(3) Using a screwdriver, detach the claw, and then detach the holder as shown in the illustration.





Text in Illustration





(4) Remove the handle by sliding and pulling it in the direction indicated by the arrow in the illustration.





(b) w/o Smart Key System:

(1) Using a screwdriver, detach the claw, and then detach the holder as shown in the illustration.





Text in Illustration





(2) Remove the handle by sliding and pulling it in the direction indicated by the arrow in the illustration.





32. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Detach the 2 claws and remove the pad.





33. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Detach the 2 claws and remove the pad.





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

(a) w/ Smart Key System:

(1) Disconnect the connector.





(2) Detach the clamp and remove the front door No. 2 wire.

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





(b) w/o Smart Key System:

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





(c) Slide the front door outside handle frame sub-assembly to detach the door handle nut and claw of the front door outside handle frame sub-assembly, and then remove the front door outside handle frame sub-assembly.

35. REMOVE FRONT DOOR LOCK OPEN ROD LH

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





36. REMOVE FRONT DOOR NO. 2 WIRE LH (w/ Smart Key System)

(a) Detach the 2 clamps and remove the front door No. 2 wire.





37. REMOVE FRONT DOOR REAR INSIDE PANEL REINFORCEMENT EXTENSION LH

(a) Remove the 2 bolts and front door rear inside panel reinforcement extension.





38. REMOVE FRONT DOOR NO. 2 STIFFENER CUSHION

(a) Remove the 2 bolts.





(b) Detach the 2 guides and remove the front door No. 2 stiffener cushion.

NOTICE:
Remove any remaining tape from the door.

Text in Illustration





39. REMOVE FRONT DOOR PANEL CUSHION

(a) Detach the 2 claws and remove the 2 front door panel cushions.





40. REMOVE FRONT DOOR CHECK ASSEMBLY

(a) Remove the bolt, 2 nuts and door check.





HINT
Remove the check through the service hole.

41. REMOVE FRONT DOOR WEATHERSTRIP LH

(a) Using a clip remover, remove the 2 clips in the illustration.





(b) Using a clip remover, detach the 17 clips and remove the weatherstrip.

HINT
If clips are damaged during removal, replace them.

42. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING LH

43. REMOVE NO. 1 BLACK OUT TAPE LH
pro multis · About Operation CHARM