Section 1041 (Front Door): Overhaul

HINT:

• The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (see STANDARD BOLT SPECIFICATIONS ).

1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 
   1. Using a screwdriver, disengage the 2 clips and remove the garnish.

   HINT:

   Tape the screwdriver tip before use.

   Fig 1: Disengaging 2 Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL 
   1. Using a screwdriver, disengage the 3 claws and remove the plug.

   HINT:

   Tape the screwdriver tip before use.

   Fig 2: Disengaging 3 Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE DOOR PULL HANDLE 
   1. Remove the screw and pull handle.
   Fig 3: Removing Screw

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FRONT ARMREST BASE PANEL UPPER 
   1. Driver's side:

      Using a screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel together with the window regulator master switch.

      HINT:

      Tape the screwdriver tip before use.

   2. Disconnect the switch connector.
   3. Remove the 3 screws and the window regulator master switch from the armrest base panel upper.
      Fig 4: Removing 3 Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Passenger's side:

      Using a screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel together with the 2 switches.

      HINT:

      Tape the screwdriver tip before use.

   5. Disconnect the switch connector.
   6. Using a screwdriver, disengage the 2 claws and remove the door control switch.
      Fig 5: Disengaging 2 Claws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      Tape the screwdriver tip before use.

   7. Using a screwdriver, disengage the 2 claws and remove the power window regulator switch.

      HINT:

      Tape the screwdriver tip before use.

5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY 
   1. Remove the screw.
   2. Using a screwdriver, disengage the 7 clips and remove the trim board.

      HINT:

      • Tape the screwdriver tip before use.
      • In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration.
      • If the clip cannot be reached with the clip remover, pull on the lower trim to remove it.
      Fig 6: Disengaging 7 Clips

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSY 
   1. Using a screwdriver, disengage claw A as shown in the illustration.

      HINT:

      Tape the screwdriver tip before use.

   2. Move the inside handle in the direction indicated by the arrow mark in the illustration. The will release the claw and allow removal of the inside handle.
   3. Disconnect the 2 cables from the inside handle.
      Fig 7: Disconnecting Cables

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE OUTER REAR VIEW MIRROR ASSY 
   1. Disconnect the mirror connector.
   2. Remove the 3 nuts and mirror.
      NOTE: Be careful when removing the nuts as the mirror may fall and become damaged.