Section 266 (Front Door): Overhaul

HINT:

• The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
• On the RH side, use the same procedures as on the LH side.

1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
   1. Using a screwdriver, disengage the clip and claw, and remove the lower frame bracket garnish.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Removing Front Door Lower Frame Bracket Garnish LH

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

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Removing Front Door Inside Handle Bezel LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT ARMREST ASSY LH 
   1. Using a screwdriver, disengage the 2 claws and 2 clips, and then remove the armrest assy from the trim board sub-assy.

      HINT:

      Tape the screwdriver tip before use.

      Fig 3: Removing Front Armrest Assy LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY 
   1. Using a screwdriver, disengage the 2 claws and 2 clips, and then remove the armrest base panel upper together with the master switch assy.

      HINT:

      Tape the screwdriver tip before use.

      Fig 4: Removing Armrest Base Panel Upper Together With Master Switch Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Disconnect the master switch connector.
   3. Remove the 3 screws and the master switch from the armrest base panel upper.
5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
   1. Remove the 2 cushion rubbers.
   2. Remove the 3 screws and the clip indicated.
   3. Using a clip remover, disengage the other 10 clips.
   4. Remove the trim board sub-assy upward.

      HINT:

      In order to prevent the door panel from being damaged, cover the parts indicated by arrow marks in Fig 5 with tape.

   5. Disconnect the 2 speaker connectors.
      Fig 5: Covering Parts With Tape

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Disconnect the 2 cables from the inside handle, as shown in Fig 6 .
      Fig 6: Disconnecting Cables From Inside Handle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   7. Remove the inner weatherstrip.
   8. Remove the No. 2 speaker (See REPLACEMENT ).
   9. Remove the stereo component speaker (See REPLACEMENT ).
   10. Remove the 2 screws and the inside handle sub-assy.
   11. Using a screwdriver, disengage the claw and remove the illumination lamp assy, as shown in Fig 7 .

       HINT:

       Tape the screwdriver tip before use.

       Fig 7: Removing Illumination Lamp Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
   NOTE: Remove the remaining tape on the door side.
   Fig 8: Removing Front Door Service Hole Cover LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
   1. Disconnect the mirror connector.
   2. Remove the 3 nuts and outer rear view mirror assy.
      NOTE: When the nuts are removed, the outer rear view mirror assy may fall and become deformed. 
      Fig 9: Removing Outer Rear View Mirror Assy LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT NO. 2 SPEAKER ASSY (See  REPLACEMENT  ) 
9. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH  
10. REMOVE FRONT DOOR BELT MOULDING LH  
11. REMOVE FRONT DOOR GLASS SUB-ASSY LH 

    HINT:

    Insert a shop rag inside the door panel to prevent the door glass sub-assy from being scratched.

    1. Open the door glass until the bolts appear in the service holes.
    2. Remove the 2 bolts holding the door glass sub-assy to the window regulator sub-assy.
       Fig 10: Removing Bolts Holding Door Glass Sub-Assy To Window Regulator Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the door glass sub-assy, as shown in Fig 11 .
       NOTE:

       • Do not damage the door glass sub-assy. 
       • When the bolts are removed, the door glass sub-assy may fall and become deformed. 

       Fig 11: Removing Door Glass Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the glass run.
12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Disconnect the window regulator connector.
    2. Remove the 6 bolts and window regulator sub-assy.
       NOTE: When the bolts are removed, the window regulator sub-assy may fall and become deformed. 

       HINT:

       Remove the window regulator sub-assy through the service hole.

       Fig 12: Removing Front Door Window Regulator Sub-Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Place matchmarks on the regulator motor gear and regulator gear.
    2. Using a torx driver (T25), remove the 3 screws and window regulator motor assy.
14. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Remove the bolt and frame sub-assy.
       Fig 13: Removing Front Door Frame Sub-Assy Rear Lower LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Remove the hole plug.
    2. Using a torx socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.
       Fig 14: Removing Front Door Outside Handle Cover LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Disconnect the door lock connector.
    2. Using a torx socket wrench (T30), remove the 3 screws and door lock assy.

       HINT:

       Remove the door lock assy through the service hole.

       Fig 15: Removing Front Door W/Motor Lock Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Pushing and pulling the outside handle assy in the direction of the arrow mark as shown in Fig 16 , remove the outside handle.
    2. Remove the outside handle pads front and rear.
       Fig 16: Removing Front Door Handle Assy Outside LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a torx socket wrench (T30), loosen the screw.
    2. Slide the outside handle frame sub-assy to remove it.

       HINT:

       Remove the outside handle frame sub-assy through the service hole.

    3. Remove the lock open rod from the outside handle frame sub-assy.
       Fig 17: Removing Front Door Outside Handle Frame Sub-Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE FRONT DOOR CHECK ASSY LH 
    1. Remove the check cover.
    2. Remove the 2 nuts, bolt and door check assy.
       Fig 18: Removing Front Door Check Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a clip remover, disengage the clips, and remove the weatherstrip.

       HINT:

       If the clips are damaged, exchange them for new clips.

21. REMOVE FRONT DOOR WIRE LH 
    1. Disconnect the wire clips.
    2. Remove the 2 bolts and door wire.
       Fig 19: Removing Front Door Wire LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL FRONT DOOR WIRE LH 
    1. Install the door wire with the 2 bolts.

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

       NOTE: In order to prevent water leakage, be sure that the lip of the rubber grommet does not turn up or is not deformed when installing the door wire. 
    2. Connect the wire clips.
       Fig 20: Installing Front Door Wire LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL FRONT DOOR CHECK ASSY LH 
    1. Apply MP grease to the sliding parts of the door check assy.
    2. Install the door check assy to the door panel with the 2 nuts.

       Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 

       HINT:

       Install the door check assy so that the rivet head is up.

    3. Apply adhesive to the threads of the bolt.

       Adhesive: 

       • Part No. 08833-00070, THREE BOND 1324 or equivalent 
       Fig 21: Applying Adhesive To Threads Of Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the door check assy to the body with the bolt.

       Torque: 30 N.m (306 kgf.cm, 22 in.lbf) 

    5. Install the check cover.
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Install the lock open rod to the outside handle frame sub-assy.
    2. Using a torx socket wrench (T30), install the outside handle frame sub-assy with the screw.

       Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

       NOTE: A cover should be inserted between the nut and the door panel. 
    3. Install the outside handle pads front and rear.
       Fig 22: Installing Lock Open Rod To Outside Handle Frame Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Pushing the outside handle assy in the direction of the arrow mark as shown in Fig 23 , install the outside handle assy.
       NOTE: If the release plate is not pulled and held when installing the outside handle assy, the release plate will interfere with the outside handle assy, and damage the release plate. 
       Fig 23: Pushing Outside Handle Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Apply MP grease to the sliding and rotating parts of the door lock assy.
    2. If reusing the door lock assy:

       Install a new door lock wire harness packing.

       NOTE:

       • If reusing a door lock assy that has been removed, replace the packing in the connecting part with a new one. 
       • Be careful that no grease and dirt sticks to the packing surface in the connecting part. 
       • Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock assy. 
    3. Insert the door lock open rod into the door lock assy, and then set it to the door panel.
       NOTE: Make sure that the outside handle link is securely engaged with the door lock assy. 
       Fig 24: Inserting Door Lock Open Rod Into Door Lock Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply adhesive to the threads of the screws.

       Adhesive: 

       • Part No. 08833-00070, THREE BOND 1324 or equivalent 
    5. Using a torx socket wrench (T30), install the door lock assy with the 3 screws.

       Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf) 

       Fig 25: Installing Door Lock Assy With Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the door lock connector.
27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Using a torx socket wrench (T30), install the outside handle cover with the screw.

       Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

       Fig 26: Installing Outside Handle Cover With Screw

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hole plug.
28. INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Install the door frame sub-assy with the bolt.

       Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf) 

       Fig 27: Installing Door Frame Sub-Assy With Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Align the matchmarks on the regulator motor gear and regulator gear.
    2. Using a torx driver (T25), install the regulator motor assy with the 3 screws.

       Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

       HINT:

       Never rotate the motor assy to the down direction until the window glass installation is done.

30. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Apply MP grease to the sliding and rotating parts of the window regulator sub-assy.
       NOTE: Do not apply grease to the spring of the window regulator sub-assy. 
       Fig 28: Applying Grease To Sliding And Rotating Parts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the window regulator sub-assy with the 6 bolts.

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

       Fig 29: Installing Window Regulator Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the window regulator connector.
       NOTE: Be careful not to drop and deform the door window regulator sub-assy as this may cause deformation. 
31. INSTALL FRONT DOOR GLASS SUB-ASSY LH 
    NOTE: Do not damage the door glass sub-assy. 
    1. Install the glass run.
    2. Insert the door glass sub-assy into the door panel along the glass run, as shown in Fig 30 .
       Fig 30: Inserting Door Glass Sub-Assy Into Door Panel Along Glass Run

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the door glass sub-assy to the window regulator sub-assy with the 2 bolts.

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

       Fig 31: Installing Door Glass Sub-Assy To Window Regulator Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Inspect operation of the power window.

       HINT:

       When the installation point of the door glass sub-assy does not match, adjust the regulator position in manual operation.

       1. Connect the power window switch to the wire harness and turn the ignition switch ON.
       2. Repeat UP and DOWN operation several times in manual operation.
32. INSTALL OUTER REAR VIEW MIRROR ASSY LH 
    1. Install the outer rear view mirror assy with the 3 nuts.

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

       Fig 32: Installing Outer Rear View Mirror Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the outer mirror connector.
33. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door panel, as shown in Fig 33 .

       Adhesive: 

       • Part No. 08850-00065, Butyl Tape Set or equivalent 
       Fig 33: Applying Butyl Tape To Door Panel

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the service hole cover.

       Dimensions: 

       DIMENSIONS CHART
       
       

       A	6.0 mm (0.236 in.)
       B	2.0 mm (0.079 in.)

       HINT:

       • 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, confirm the sealing condition.