Last Modified: 08-28-2024 6.11:8.1.0 Doc ID: RM100000000VK8G
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 11/2017]
Title: DOOR / HATCH: FRONT DOOR: DISASSEMBLY; 2016 - 2017 MY Sienna [12/2015 - 11/2017]

DISASSEMBLY

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for both the RH and LH sides.
  • The procedure described below is for the RH side.

PROCEDURE

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 (See page 2016 MY Sienna [12/2015 - 08/2016]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION 2017 MY Sienna [08/2016 - 11/2017]; INTRODUCTION: REPAIR INSTRUCTION: INITIALIZATION ).

2. REMOVE FRONT DOOR ARMREST BASE PANEL ASSEMBLY

(a) Using a moulding remover, disengage the 5 claws and 2 clips.

(b) Disconnect the 2 connectors to remove the front door armrest base panel assembly.

3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG

(a) Using a moulding remover, disengage the 3 claws to remove the front door inside handle bezel plug.

4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Disengage the clip and 2 guides to remove the front door lower frame bracket garnish.

5. REMOVE FRONT DOOR NO. 1 STIFFENER CUSHION

(a) Remove the screw and front door No. 1 stiffener cushion.

6. REMOVE COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)

2016 - 2020 MY Sienna [12/2015 -        ]; LIGHTING (INT): DOOR COURTESY LIGHT: REMOVAL+

7. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Remove the 2 screws.

(b) Disengage the 10 clips.

(c) Disconnect the connector. (for Driver Side w/ Memory)

(d) Disconnect the front door lock remote control cable and front door inside locking cable to remove the front door trim board sub-assembly.

8. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Disengage the 2 claws to remove the front door inside handle sub-assembly.

9. REMOVE FRONT DOOR GLASS INNER WEATHERSTRIP

(a) Disengage the 8 claws to remove the front door glass inner weatherstrip from the front door trim board sub-assembly, as shown in the illustration.

10. REMOVE SEAT MEMORY SWITCH (for Driver Side with Memory)

HINT:

Use the same procedure as for the LH side (See page 2016 - 2020 MY Sienna [12/2015 -        ]; SEAT: SEAT MEMORY SWITCH: REMOVAL+ ).

11. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)

2016 - 2020 MY Sienna [12/2015 -        ]; MIRROR (EXT): OUTER MIRROR CONTROL ECU: REMOVAL+

12. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

2016 - 2020 MY Sienna [12/2015 -        ]; AUDIO / VIDEO: FRONT DOOR SPEAKER: REMOVAL+

13. REMOVE SIDE AIRBAG SENSOR

2016 - 2020 MY Sienna [12/2015 -        ]; SUPPLEMENTAL RESTRAINT SYSTEMS: SIDE AIRBAG SENSOR: REMOVAL+

14. REMOVE FRONT DOOR SERVICE HOLE COVER

(a) Remove the bolt to disconnect the ground wire.

(b) Disengage the clamps.

(c) Remove the front door service hole cover.

NOTICE:

Remove any butyl tape remaining on the door side.

15. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY

2016 - 2017 MY Sienna [12/2015 - 11/2017]; MIRROR (EXT): OUTER REAR VIEW MIRROR: REMOVAL+

16. REMOVE FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

HINT:

Use the same procedure as for the LH side (See page 2016 - 2020 MY Sienna [12/2015 -        ]; EXTERIOR PANELS / TRIM: FRONT DOOR BELT MOULDING: REMOVAL+ ).

17. REMOVE FRONT DOOR CHECK ASSEMBLY

(a) Remove the 2 nuts and bolt, then remove the front door check assembly.

NOTICE:

Do not drop or damage the front door check assembly when removing the nuts and bolt.

HINT:

Remove the front door check assembly through the service hole.

18. REMOVE FRONT DOOR WEATHERSTRIP

(a) Disengage the 18 clips to remove the front door weatherstrip.

19. REMOVE FRONT DOOR GLASS RUN

(a) Remove the front door glass run.

20. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Remove the service hole cover.

Text in Illustration

*1

Service Hole Cover

(b) Remove the 3 bolts, screw and front door front lower frame sub-assembly.

21. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY

(a) Connect the power window regulator switch assembly.

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

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

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

(e) Disconnect the power window regulator switch assembly.

(f) Remove the 2 bolts.

NOTICE:

Do not drop or damage the front door glass sub-assembly when removing the bolts.

(g) Remove the front door glass sub-assembly in the direction indicated by the arrows in the illustration.

NOTICE:

Do not drop or damage the front door glass sub-assembly.

22. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

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

23. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

(a) Disconnect the connector.

(b) Loosen the bolt A.

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

NOTICE:

Do not drop or damage the front door window regulator sub-assembly when removing the bolts.

HINT:

Remove the front door window regulator sub-assembly through the service hole.

(d) Remove the bolt A from the window regulator sub-assembly.

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

(a) Remove the hole plug.

Text in Illustration

*1

Hole Plug

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

(c) Disengage the 2 claws to remove the front door outside handle cover from the lock cylinder.

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

(a) Remove the hole plug.

Text in Illustration

*1

Hole Plug

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

26. REMOVE FRONT DOOR LOCK ASSEMBLY

2016 - 2017 MY Sienna [12/2015 - 11/2017]; DOOR LOCK: FRONT DOOR LOCK: REMOVAL+

27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System)

(a) Pull up the door handle holder in the direction indicated by the arrow as shown in the illustration.

(b) Remove the front door outside handle assembly in the direction indicated by the arrow as shown in the illustration.

28. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System)

(a) Using a screwdriver, disengage the 4 claws to remove the connector cover.

(b) Disconnect the connector.

(c) Pull up the door handle holder in the direction indicated by the arrow as shown in the illustration.

(d) Remove the front door outside handle assembly in the direction indicated by the arrow as shown in the illustration.

29. REMOVE FRONT DOOR OUTSIDE HANDLE FRONT PAD

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

30. REMOVE FRONT DOOR OUTSIDE HANDLE REAR PAD

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

31. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System)

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

(b) Slide the front door outside handle frame sub-assembly to remove it.

32. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System)

(a) Disengage the 3 clamps.

(b) Disconnect the connector.

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

(d) Slide the front door outside handle frame sub-assembly to remove it.

33. REMOVE FRONT DOOR WIRE (w/ Smart Key System)

(a) Disengage the clamp to remove the front door wire from the front door outside handle frame sub-assembly.

34. REMOVE DOOR FRAME GARNISH

(a) Disengage the clamp to remove the door frame garnish.

35. REMOVE CUSHION

(a) Remove the cushion.