Toyota CH-R Service Manual: Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during the front door removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative when not Performed	Link
Disconnect cable from negative battery terminal	Initialize back door lock	Power door lock control system
	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)
		Pre-collision system
Front door window regulator assembly Front door glass sub-assembly Front door glass run	Initialize Power Window Control System	Auto up and down function Jam protection function Catch protection function Remote control function Key-linked function Wireless transmitter-linked function Key-off operation function Window open warning function

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read Precaution thoroughly before servicing.

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NOTICE:

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 notices before proceeding with work.

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2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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NOTICE:

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

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3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG

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

Remove in this Direction

4. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT ARMREST BASE UPPER PANEL (for Driver Side)

(a) Disengage the claws, clips and guides as shown in the illustration.

Remove in this Direction

(b) Disconnect the 2 connectors to remove the multiplex network master switch assembly with front armrest base upper panel.

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

(a) Disengage the claws, clips and guides as shown in the illustration.

Remove in this Direction

(b) w/o Rear Seat Side Airbag:

(1) Disconnect the connector to remove the power window regulator switch assembly with front armrest base upper panel.

(c) w/ Rear Seat Side Airbag:

(1) Disconnect the 2 connectors to remove the power window regulator switch assembly with front armrest base upper panel.

6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Remove the 3 screws.

(b) Disengage the clips (A), other clips and guide as shown in the illustration.

*a	Clip (A)
	Place Hands Here
	Remove in this Direction

(c) Disengage the front door trim board sub-assembly with the front door glass inner weatherstrip and front door belt seal as shown in the illustration.

Remove in this Direction

(d) w/ Illumination:

(1) Disconnect the connector.

(e) Disengage the guides to disconnect the front door inside locking cable assembly and front door lock remote control cable assembly to remove the front door trim board sub-assembly as shown in the illustration.

*1	Front Door Inside Locking Cable Assembly
*2	Front Door Lock Remote Control Cable Assembly
	Remove in this Direction

7. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Disengage the claw and guides to remove the front door inside handle sub-assembly.

8. REMOVE NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY (w/ Illumination)

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9. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Disengage the clips to remove the front door lower frame bracket garnish.

10. REMOVE FRONT DOOR GLASS INNER WEATHERSTRIP

(a) Disengage the claws remove the front door glass inner weatherstrip with the front door belt seal as shown in the illustration.

Remove in this Direction

11. REMOVE FRONT DOOR BELT SEAL

(a) Remove the front door belt seal from the front door glass inner weatherstrip as shown in the illustration.

Remove in this Direction

12. REMOVE FRONT DOOR VENT SEAL

(a) Remove the front door vent seal.

13. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY

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14. REMOVE OUTER MIRROR PROTECTOR

(a) Remove the 2 screws.

Remove in this Direction

(b) Disengage the claws to remove the outer mirror protector as shown in the illustration.

15. REMOVE FRONT DOOR SERVICE HOLE COVER

(a) Turn the 3 door weatherstrip clips 45° and remove it clips as shown in the illustration.

(b) Disengage the clips to remove the front door service hole cover.

16. REMOVE DOOR SIDE AIRBAG SENSOR (w/ Airbag Sensor)

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17. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY

(a) Remove the hole plug.

(b) for Driver Side:

(1) Connect the multiplex network master switch assembly.

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

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

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

(5) Disconnect the multiplex network master switch assembly.

(c) for Front Passenger Side:

(1) Connect the power window regulator switch assembly.

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

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

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

(5) Disconnect the power window regulator switch assembly.

(d) Remove the 2 bolts. NOTICE: After the bolts are removed, do not allow the front door glass sub-assembly to fall.

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

	Remove in this Direction (1)
	Remove in this Direction (2)

NOTICE:

Do not damage the front door glass sub-assembly.

18. REMOVE NO. 2 FRONT DOOR SERVICE HOLE COVER

(a) Disengage the claws to remove the No. 2 front door service hole cover.

19. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY

(a) Disconnect the connector.

*a Temporary Bolt

(b) Loosen the temporary bolt.

NOTICE:

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

(c) Remove the 5 bolts and front door window regulator sub-assembly.

(d) Remove the temporary bolt from the front door window regulator assembly.

20. REMOVE DOOR FRAME UPPER GARNISH

(a) Disengage the guides to remove the door frame upper garnish.

21. REMOVE FRONT DOOR GLASS RUN

(a) Remove the front door glass run.

22. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Raise up the front door weatherstrip.

(b) Remove the screw.

(c) Remove the 2 bolts and front door front lower frame sub-assembly.

(d) Install the front door weatherstrip.

23. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Remove the bolt.

Remove in this Direction

(b) Disengage the guide to remove the front door rear lower frame sub-assembly as shown in the illustration.

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

(a) Remove the hole plug.

*1	Hole Plug
	Remove in this Direction

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

(c) Remove the front door outside handle cover with front door lock cylinder assembly as shown in the illustration.

(d) Using a screwdriver with its tip wrapped in protective tape, disengage the claw and guides to remove the front door outside handle cover as shown in the illustration.

*a	Protective Tape
	Remove in this Direction

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

(a) Remove the hole plug.

*1	Hole Plug
	Remove in this Direction

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

(c) Disengage the claws to remove the front door outside handle cover as shown in the illustration.

26. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY

(a) w/ Smart Key System: (1) Disengage the claws. (2) Using a screwdriver with its tip wrapped in protective tape, disconnect the connector.

*a Protective Tape

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

Remove in this Direction

27. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Disengage the claws and guide to remove the front door front outside handle pad as shown in the illustration.

Remove in this Direction

28. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Disengage the guides to remove the front door rear outside handle pad as shown in the illustration.

Remove in this Direction

29. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY

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30. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) w/ Smart Key System:

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

*a	Grommet
*b	Guide
	Remove in this Direction

(2) Disengage the grommet and guides to separate the front door outside handle frame sub-assembly as shown in the illustration.

(3) Disengage the clamps and guide to remove the front door outside handle frame sub-assembly.

*a Guide *b Clamp

(b) w/o Smart Key System:

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

*a	Grommet
*b	Guide
	Remove in this Direction

(2) Disengage the grommet and guides to remove the front door outside handle frame sub-assembly as shown in the illustration.

31. REMOVE FRONT DOOR LOCK OPEN ROD

(a) Disengage the snap to remove the front door lock open rod from the front door outside frame sub-assembly as shown in the illustration.

*a	Snap
	Remove in this Direction (1)
	Remove in this Direction (2)

32. REMOVE FRONT DOOR CHECK ASSEMBLY

(a) Remove the 3 bolts and front door check assembly.

33. REMOVE FRONT DOOR WEATHERSTRIP

(a) Using a clip remover, disengage the clip (A) and other clips to remove the front door weatherstrip.

*a Clip (A)

34. REMOVE FRONT DOOR DUST PROOF SEAL

(a) Remove the 3 front door dust proof seals.

35. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

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36. REMOVE FRONT DOOR FIX WINDOW GLASS

(a) Remove the front door fix window glass with front door fix window weatherstrip as shown in the illustration.

Remove in this Direction

37. REMOVE FRONT DOOR FIX WINDOW WEATHERSTRIP

(a) Remove the front door fix window weatherstrip from the front door fix window glass.

38. REMOVE FRONT DOOR PANEL CUSHION

(a) Using a clip remover, disengage the claws to remove the 2 front door panel cushions.

39. REMOVE FRONT DOOR OUTSIDE MOULDING

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40. REMOVE FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

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41. REMOVE HOLE CAP

(a) Remove the hole cap.

42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY

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43. REMOVE FRONT DOOR SCUFF PLATE

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44. REMOVE COWL SIDE TRIM BOARD

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45. REMOVE FRONT DOOR FRONT WINDOW FRAME MOULDING

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46. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING

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47. REMOVE NO. 4 FRONT DOOR STRIPE

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48. REMOVE FRONT DOOR OUTSIDE STRIPE

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49. REMOVE NO. 2 FRONT DOOR STRIPE

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