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Section 446 (Front Door): Overhaul

WARNING: This page is about a different car, the 2003 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • 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 
      NOTE:

      Tape the screwdriver tip before use.

      Fig 1: Removing Front Door Lower Frame Bracket Garnish LH
      G02814207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the lower frame bracket garnish.
  2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH 
      NOTE:

      Tape the screwdriver tip before use.

      Fig 2: Removing Front Door Inside Handle Bezel LH
      G02814208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, disengage the 3 claws, and remove the inside handle bezel.
  3. REMOVE FRONT ARMREST ASSEMBLY LH 
      NOTE:

      Tape the screwdriver tip before use.

      Fig 3: Removing Front Armrest Assembly LH
      G02814209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disengage the claws, and remove the armrest from the trim board.
  4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH 
      NOTE:

      In order to prevent the door from being damaged, cover the parts indicated by arrow marks in Fig 4 with tape.

      Fig 4: Removing Trim Board Sub-Assembly LH
      G02814210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 cushion rubbers.
    2. Remove the 2 screws and clips.
    3. Using a clip remover, remove the 11 clips.
    4. Remove the trim board upward.
    5. Disconnect the 2 cables from the inside handle as shown in Fig 5.
      Fig 5: Disconnecting Cables From Inside Handle
      G02814211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the inner weatherstrip.
    7. Remove the 3 screws and power window master switch.
      8. NOTE:

      Tape the screwdriver tip before use.

      Fig 6: Disengaging Claws Using A Screwdriver
      G02814212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a screwdriver, disengage the 4 claws.
    9. Remove the power mirror switch, as shown in Fig 6.
  5. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    NOTE: Remove the remaining tape on the door side.
    Fig 7: Removing Remaining Tape
    G02814213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH 
    1. Disconnect the outer rear view mirror connector.
      2. CAUTION: When the nuts are removed, the outer rear view mirror might drop and be deformed.
      Fig 8: Removing Outer Rear View Mirror Assembly LH
      G02814214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and outer rear view mirror.
  7. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY  See FRONT NO. 1 SPEAKER ASSEMBLY .
  8. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY 
    1. Disconnect the speaker connector.
    2. Remove the 2 bolts and No. 2 speaker.
      Fig 9: Removing Front No. 2 Speaker Assembly
      G02814215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and speaker mounting No. 1 bracket.
  9. REMOVE FRONT DOOR WINDOW FRAME MOLDING REAR LH  See REPLACEMENT .
  10. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH  See FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH .
    Fig 10: Removing Front Door Glass Sub-Assembly LH
    G02814216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH 
    NOTE:

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

    1. Open the door glass until the bolts appear in the service holes.
    2. Remove the 2 bolts and holding the door glass.
    3. Remove the door glass, as shown in Fig 11.
      Fig 11: Removing Door Glass
      G02814217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the door glass.
      • When the bolts are removed, the door glass might drop and be deformed.
    4. Remove the door glass run.
  12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 
    1. Disconnect the window regulator connector.
      2. CAUTION: When the bolts are removed, the window regulator might drop and be deformed.
      Fig 12: Removing Front Door Window Regulator Sub-Assembly LH
      G02814218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and window regulator.
    NOTE: Remove the window regulator through the service hole.
  13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 
    1. Place matchmarks on the window regulator motor gear and regulator gear.
    2. Using a Torx driver (T25), remove the 3 screws and window regulator motor.
  14. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH 
    1. Remove the bolt and frame rear lower.
      Fig 13: Removing Front Door Frame Sub-Assembly Rear Lower LH
      G02814219Courtesy 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
      G02814220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH 
    1. Disconnect the door lock connector.
    2. Using a Torx socket wrench (T30), remove the 3 screws and door lock.
      Fig 15: Removing Front Door W/Motor Lock Assembly LH
      G02814221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Remove the door lock through the service hole.

    3. Remove the door lock wire harness packing.
  17. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH 
    1. Pushing and pulling the outside handle in the arrow mark direction in Fig 16, remove the outside handle.
      Fig 16: Removing Front And Rear Outside Handle LH
      G02814222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the outside handle pad front and rear.
  18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Using a Torx socket wrench (T30), loosen the screw.
      2. NOTE:

      Remove the outside handle frame through the service hole.

      Fig 17: Removing Front Door Outside Handle Frame LH
      G02814223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the outside handle frame forward to remove it.
  19. REMOVE FRONT DOOR CHECK ASSEMBLY LH 
    1. Remove the 2 nuts, bolt and the door check.
      Fig 18: Removing Front Door Check Assembly LH
      G02814224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DOOR WEATHERSTRIP LH 
      NOTE:

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

    1. Using a clip remover, disengage the clips and remove the weatherstrip.
  21. REMOVE FRONT DOOR WIRE LH 
    1. Disconnect the door wire clips.
    2. Remove the 2 bolts and door wire.
      Fig 19: Removing Front Door Wire LH
      G02814225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FRONT DOOR WIRE LH 
    1. Install the door wire with the 2 bolts.
      Fig 20: Installing Front Door Wire LH
      G02814226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 door wire clips.
  23. INSTALL FRONT DOOR CHECK ASSEMBLY LH 
    1. Apply MP grease to the sliding parts of the door check.
    2. Install the door check to the door panel with the 2 nuts.
      Fig 21: Installing Front Door Check Assembly LH
      G02814227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Apply adhesive to the bolt.

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

      4. NOTE:

      Install the door check so that rivet head is up.

    4. Install the door check to the body panel with the bolt.

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

  24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Using a Torx socket wrench (T30), install the outside handle frame with the screw.
      Fig 22: Installing Front Door Outside Handle Frame LH
      G02814228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.0 N.m (41 kgf.cm, 35 in.lbf) 

    2. Install the outside handle pad front and rear.
  25. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH 
    1. Apply MP grease to the sliding and rotating parts of the door lock.
    2. Install a new door lock wire harness packing.
      NOTE:
      • If reusing the door lock that is removed, replace the packing in the connecting part with a new one.
      • Be careful that no grease and dirt will stick to the packing surface in the connecting part.
      • Reusing the packing that is removed or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock.
    3. Insert the outside handle link into the lock with the door motor, and then set it to the door panel.
      NOTE: Make sure that the outside handle link is securely engaged with the lock assembly.
    4. Apply adhesive to the 3 screws.
      Fig 23: Installing Door Lock Connector
      G02814229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

    5. Using a Torx socket wrench (T30), install the door lock with the 3 screws.

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

    6. Connect the door lock connector. 
  26. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Using a Torx socket wrench (T30), install the outside handle cover with the screw.
      Fig 24: Installing Front Door Outside Handle Cover LH
      G02814230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.0 N.m (41 kgf.cm, 35 in.lbf) 

    2. Install the hole plug.
  27. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH 
    1. Install the door frame with the bolt.
      Fig 25: Installing Front Door Frame Sub-Assembly Rear Lower LH
      G02814231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  28. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 
    1. Align the matchmarks on the regulator motor gear and regulator gear.
    2. Using a Torx driver (T25), install the door regulator motor with the 3 screws.

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

    NOTE:

    Never rotate the motor to the down direction until the window glass installation has been done.

  29. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 
      NOTE: Do not apply grease to the spring of the window regulator.
      Fig 26: Identifying Grease Locations
      G02814232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Apply MP grease to the sliding and rotating parts of the window regulator.
      2. CAUTION: Be careful not drop and deform the door window regulator.
      Fig 27: Installing Window Regulator
      G02814233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the window regulator with the 6 bolts.

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

    3. Connect the window regulator connector.
  30. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH 
    NOTE: Do not damage the door glass.
    1. Install the glass run.
    2. Insert the door glass into the door panel along the glass run, as shown in Fig 28.
      Fig 28: Inserting Door Glass Into Door Panel
      G02814234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the door glass to the window regulator with the 2 bolts.
      Fig 29: Identifying Door Glass To Window Regulator Bolts
      G02814235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Inspect operation of the power window.
    NOTE:

    When the installation point of the door glass does not match, adjust the regulator position in the 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 the manual operation.
  31. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY 
    1. Install the No. 1 speaker bracket with the 2 bolts.
      Fig 30: Identifying Front Speaker Bolts
      G02814236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the speaker connector.
    3. Install the No. 2 speaker with the 2 bolts.

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

  32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH 
    1. Install the outer rear view mirror with the 3 nuts.
      Fig 31: Identifying Outer Rear View Mirror Assembly LH Nuts
      G02814237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the outer rear view mirror connector.
  33. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door, as shown in Fig 32.
      Fig 32: Applying Butyl Tape To Door
      G02814238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent 

    2. Install the service hole cover.
      BUTYL TAPE INSTALLATION DIMENSIONS

      Application Specification
      A 6 mm (0.236 in.)
      B 2 mm (0.079 in.)
    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, check the sealing condition.
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