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Front Door: Overhaul

NOTE:
  • Installation is in the reverse order of removal. But, the installation is indicated only when it has a point.
  • In the LH side, work in the same procedure as in the RH side.
  1. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSY 
    1. Using a screwdriver, remove the front armrest assembly.
    NOTE: Tape the screwdriver tip before use.
    Fig 1: Removing Front Armrest Assembly
    G03387805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE DOOR INSIDE HANDLE BEZEL NO. 2 LH 
    1. Using a screwdriver, remove the door inside handle bezel.
    NOTE: Tape the screwdriver tip before use.
    Fig 2: Removing Front Door Inside Handle Bezel
    G03387806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FRONT DOOR WINDOW UPPER BRACKET GARNISH LH 
    1. Remove the upper bracket garnish.
    Fig 3: Removing Upper Bracket Garnish
    G03387807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
    1. Remove the 8 screws.
    2. Remove the clip.
    3. Using a screwdriver, remove the door panel.
      NOTE: Tape the screwdriver tip before use.
    4. Disconnect the 2 cables from the inside handle.
    Fig 4: Disconnecting Cables From Inside Handle
    G03387808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
    1. Disconnect the connector.
    2. Remove the 3 bolts and the outer rear view mirror assembly.
  6. REMOVE MULTIPLEX NETWORK DOOR ECU FRONT LH 
    1. Remove the 2 screws and door ECU.
  7. REMOVE FRONT DOOR WEATHERSTRIP NO. 2 
    1. Remove the 2 clips and weatherstrip No. 2.
  8. REMOVE FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH 
    1. Remove the 2 bolts and lower door frame.
    Fig 5: Removing Lower Door Frame
    G03387809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT DOOR GLASS RUN LH 
    1. Remove the door glass run.
  10. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    1. Remove the service hole cover.
  11. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a screwdriver, remove the door weatherstrip.
    NOTE: Tape the screwdriver tip before use.
    Fig 6: Removing Door Weatherstrip
    G03387810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT DOOR BELT MOULDING LH 
  13. REMOVE FRONT DOOR SERVICE HOLE COVER NO. 2 LH 
    1. Remove the 4 screws and door service hole cover No.2.
  14. REMOVE FRONT DOOR GLASS SUB-ASSY LH 
    NOTE: 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 3 nuts and door glass.
      Fig 7: Removing Door Glass Retaining Nuts
      G03387811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the door glass.
    NOTE: Pull the glass upward to remove it.
  15. REMOVE FRONT DOOR WINDOW REGULATOR ASSY LH 
    1. Disconnect the connector.
    2. Remove the 7 nuts and window regulator.
    Fig 8: Removing Window Regulator
    G03387812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Disconnect the connectors.
    2. Disconnect the links from the outside handle.
    3. Using a Torx socket wrench (T30), remove the 4 Torx screws and door lock.
  17. APPLICATION BODY GREASE 
    1. Apply MP grease to the sliding and rotating parts of the regulator assembly and door lock.
  18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a Torx socket wrench, remove the screw and door lock key cylinder.
      Fig 9: Removing Torx Screw
      G03387813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the outside handle from the outside handle frame.
    3. Remove the nut and front door outside handle frame.
  19. REMOVE STEREO COMPONENT SPEAKER ASSY 
    1. Remove the 4 screws and speaker.
  20. REMOVE FRONT NO. 2 SPEAKER ASSY 
    1. Remove the 2 screws and front speaker.
  21. REMOVE DOOR GLASS FEMALE STABILIZER LH 
    1. Remove the 2 screws and glass female stabilizer.
  22. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Using a Torx socket wrench (T30), install the front door lock assembly with the 4 screws.

      Torque: 5.5 N.m (56 kgf.cm, 48 in.lbf) 

    2. Connect the link to the outside handle.
    3. Connect the connector.
  23. INSTALL FRONT DOOR WINDOW REGULATOR ASSY LH 
    1. Install the front door window regulator with the 7 nuts.

      Upper side: 

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

      Lower side: 

      Torque: 13.0 N.m (133 kgf.cm, 10 ft.lbf) 

      Motor side: 

      Torque: 5.5 N.m (56 kgf.cm, 48 in.lbf) 

    2. Install the power window regulator and door glass.
    3. Connect the power window switch to the wire harness and turn the ignition switch ON.
    4. Fully close the door glass by a manual operation.
      Fig 10: Closing Door Glass By Manual Operation
      G03387814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. By using a round bar (PHY2 mm) keep the reset switch pressed.
    6. Fully open the door glass by a manual operation with the reset switch pressed.
    7. Take the round bar away from the reset switch and then fully close the door glass by a manual operation.
    8. Check if AUTO UP --> AUTO DOWN operates in the automatic operation.
      NOTE:
      • Note that the jam protection function does not operate just after resetting.
      • Reset the regulator again when performing the reverse operation after closing the window fully by AUTO UP operation.
    9. Check the power window function.
  24. INSPECT FRONT DOOR GLASS SUB-ASSY LH 
    1. Check that the clearance is within the standard value.
    Fig 11: Checking Clearance Standard Value
    G03387815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. ADJUST FRONT DOOR GLASS SUB-ASSY LH 
    1. Fitting adjustment of the front door glass at the upper end in the horizontal direction.
      1. Loosen the 2 nuts at the bottom of the window regulator assembly and of the front door mirror bracket.
      2. Adjust the fitting of the front door glass at the upper end in the horizontal direction as shown in the illustration, by turning the stud bolt with a hexagon wrench of 2 sides and 4 mm width.
        Fig 12: Adjusting Front Door Glass Position
        G03387816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE: When the stud bolt is loosened, the upper end of the glass leans to the inside of the vehicle. When the stud bolt is tightened, the upper end leans to the outside.
      3. Tighten the 2 nuts.
    2. Fitting adjustment at the bottom of the front door glass RH in the horizontal direction.
      1. Loosen the 2 nuts.
      2. Adjust the fitting at the bottom of the front door glass RH in the horizontal direction as shown in the illustration.
        3. Fig 13: Fitting Adjustment At Bottom Of Front Door Glass RH In Horizontal Direction
        G03387817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Tighten the 2 nuts.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

    3. Slant adjustment of the front door glass RH (when fully closed) in the up/down direction and in the front/rear direction.
      1. Loosen the installation bolts for the front door glass stopper, and install the glass temporarily in the upper end.
        2. Fig 14: Loosening Installation Nuts For Front Door Glass RH
        G03387818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Loosen the 3 installation nuts for the front door glass RH.
      3. By operating the power window regulator master switch assembly, stop the front door glass RH in approximately 3 mm before the full-closed position.
      4. Adjust the slant of the front door glass RH in the up/down direction and in the front/rear direction as shown in the illustration, holding it up.
        Fig 15: Adjusting Slant Of Front Door Glass RH In Up/Down Direction
        G03387819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. While holding the front door glass RH in the full-closed position, press it lightly toward the front door glass stopper and then tighten the bolts and nuts properly.

      Torque: 11.5 N.m (117 kgf.cm, 8.5 ft.lbf) 

  26. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Install the service hole cover to the door panel.
    NOTE:
    • When installing the service hole cover, pull out the links and connectors through the service hole cover.
    • There should be no wrinkles or folds after attaching the service hole cover.
    • After attaching the service hole cover, sealing condition should be confirmed.
    Fig 16: Installing Service Hole Cover To Door
    G03387820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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