Section 803 (Front Door): Overhaul

HINT:

• Installation is in the reverse order of removal. But the installation is indicated only when it has a point.
• In the RH side, work in the same procedure as in the LH side.

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY 
   1. Using a screwdriver, remove the power window regulator master switch assembly then disconnect the connector.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Removing Power Window Regulator Master Switch Assembly Then Disconnect Connector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
   1. Using a screwdriver, remove the front door lower frame bracket garnish.

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Removing Front Door Lower Frame Bracket Garnish

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH 
   1. Using a screwdriver, remove the front door inside handle bezel plug.

      HINT:

      Tape the screwdriver tip before use.

      Fig 3: Removing Front Door Inside Handle Bezel Plug Using Screwdriver

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
   1. Remove the 2 screw.
   2. Using a screwdriver, remove the front door trim board.

      HINT:

      Tape the screwdriver tip before use.

   3. Remove the inside handle then disconnect the 2 cables from the front door lock assembly.
   4. Disconnect the connector.
      Fig 4: Removing Front Door Trim Board

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
   1. Disconnect each connector and remove the front door service hole cover.
      NOTE: Remove the remained tape on the body side.
6. REMOVE FRONT NO.1 SPEAKER ASSY 
   1. Disconnect the connector.
   2. Remove the 3 bolt and the front No.1 speaker assembly.
7. REMOVE FRONT DOOR GLASS SUB-ASSY LH 

   HINT:

   Insert a shop rag inside the door panel to prevent scratching the glass.

   1. Open the door glass until the bolts appear in the service hole.
   2. Remove the 2 bolts and door glass.
      NOTE: Do not damage the door glass.

      HINT:

      Pull the glass upward to remove it.

      Fig 5: Removing 2 Bolts And Door Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
   1. Disconnect the connector.
   2. Loosen the temporarily installed bolt.
      NOTE: When the temporarily installed bolt is removed, the front door window regulator might drop and be deformed.
   3. Remove the 5 bolts and front door window regulator.
9. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH 
   1. Using a torx wrench (T25), remove the 3 screws and the motor assembly.
10. REMOVE FRONT DOOR GLASS RUN LH 
11. REMOVE FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH 
    1. Remove the bolt and the front door frame sub-assy front lower.
12. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Remove the bolt and the front door frame sub-assy rear lower.
13. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Remove the hole plug
    2. Using a Torx wrench (T30), loosen the screw and remove the front door outside handle cover with the door lock key cylinder installed.
       Fig 6: Removing Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Disconnect the connector.
    2. Using a Torx wrench (T30), remove the 3 screws and the front door w/ motor lock assembly.
15. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Pushing the outside handle in the arrow mark direction in the illustration, remove the front door outside handle.
       Fig 7: Pushing Outside Handle In Arrow Mark Direction

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE DOOR OUTSIDE HANDLE SUB-ASSY LH 
    1. Using a Torx wrench (T30), loosen the screw.
    2. Using pliers, disengage the clips and remove the front door outside handle, as shown in the illustration.
       NOTE: Be sure to remove the outside handle together with the clips, because the clips will be damaged if the clips remain attached to the door panel.