Section 463 (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 SUSPENSION CONTROL SYSTEM ).

1. REMOVE DOOR INSIDE HANDLE BEZEL NO.2 LH 
   1. Using a screwdriver, disengage the 3 claws and remove the bezel.

      HINT:

      Tape the screwdriver tip before use.

      Fig 1: Removing Bezel

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Driver's side: REMOVE FRONT DOOR ARMREST BASE PANEL UPPER 
   1. Using a screwdriver, pry the armrest panel assembly.

      HINT:

      Tape the screwdriver tip before use.

   2. Remove the 3 screws and power window regulator master switch.
   3. Remove the 2 screws and armrest base panel lower from the armrest base panel upper.
      Fig 2: Removing Screws And Armrest Base Panel Lower

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Passenger's side: REMOVE FRONT DOOR ARMREST BASE PANEL UPPER 
   1. Using a screwdriver, pry the armrest panel assembly.

      HINT:

      Tape the screwdriver tip before use.

   2. Using a screwdriver, disengage the 2 claws and remove the lock control switch from the armrest panel assembly.

      HINT:

      Tape the screwdriver tip before use.

   3. Using a screwdriver, disengage the 2 claws and remove the power window switch from the armrest assembly.

      HINT:

      Tape the screwdriver tip before use.

      Fig 3: Removing Front Door Armrest Base Panel Upper

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Remove the 2 screws and armrest base panel lower from the armrest base panel upper.
4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
   1. Remove the 7 screws as shown in the illustration.
      Fig 4: Removing Screws

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using a screwdriver, disengage the 4 clips.
   3. Remove the trim board upward.

      HINT:

      • 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.
      • Tape the screwdriver tip before use.
        Fig 5: Disengaging Clips

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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Remove the screw.
   6. Using a screwdriver, disengage the 2 claws.

      HINT:

      Tape the screwdriver tip before use.

   7. Remove the inside handle.
      Fig 7: Removing Inside Handle

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   8. Using a screwdriver, disengage the 2 clips and remove the courtesy light.
   9. Remove the 2 screws and seat memory switch.
   10. Remove the 3 screws and vent seal.
   11. Remove the 2 screws and door pocket.
       Fig 8: Removing Screws And Door Pocket

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE DOOR FRAME GARNISH LH 
   1. Using a clip remover, disengage the 2 clips and remove the garnish.
      Fig 9: Disengaging Clips And Removing Garnish

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
   1. Remove the 2 screws and door electrical key oscillator.
   2. Remove the service hole cover.
      NOTE: Remove the remaining tape on the door side.
      Fig 10: Removing Remaining Tape On Door Side

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
   1. Disconnect the connector.
   2. Remove the 3 bolts and mirror.
      NOTE: Be careful when removing the bolts as the mirror may fall and become damaged.
      Fig 11: Disconnecting Connector

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT DOOR ECU 
   1. Disconnect the connector.
   2. Remove the 2 screws and ECU.
9. REMOVE FRONT NO.1 SPEAKER ASSY (see  REPLACEMENT  ) 
10. REMOVE FRONT DOOR BELT MOULDING ASSY LH (see  REPLACEMENT  ) 
11. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH 
12. REMOVE FRONT DOOR WINDOW FRAME MOULDING FRONT LH 
13. REMOVE FRONT DOOR GLASS RUN LH 
    1. Using a drill of less than "OSLASH" 4 mm (0.16 in.), drill out the heads of the 5 rivets and remove the glass run.
       NOTE:

       • Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
       • Be careful as the cut rivet will become very hot.
    2. Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
    3. Using a vacuum cleaner, remove the drilled rivets and dust from the inside of the door.
       Fig 12: Removing Drilled Rivets And Dust From Inside Of Door

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DOOR GLASS SUB-ASSY LH 

    HINT:

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

    1. Move the door glass until the bolts appear in the service holes.
    2. Remove the 2 bolts holding the door glass to the window regulator.
       NOTE: Be careful when removing the bolts as the glass may fall and become damaged.
       Fig 13: Removing Bolts Holding Door Glass To Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Move the glass as shown in the illustration to remove it.
       NOTE: Be careful not to damage the glass.
       Fig 14: Removing Glass

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Disconnect the window regulator connector.
    2. Remove the 6 bolts and window regulator.

       HINT:

       Remove the window regulator through the service hole.

       NOTE: Be careful when removing the bolts as the window regulator may fail and become damaged.
       Fig 15: Removing Window Regulator Through Service Hole

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH FRONT 
    1. Place matchmarks on the window regulator motor bracket and regulator gear.
       Fig 16: Placing Matchmarks On Window Regulator Motor Bracket And Regulator Gear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a Torx driver (T25), remove the 3 screws and motor.
       Fig 17: Removing Screws And Motor

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Remove the 2 bolts and frame.
       NOTE: Be careful when removing the bolts as the frame may fall and become damaged.

       HINT:

       Remove the frame through the service hole.

       Fig 18: Removing Frame Through Service Hole

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH 
    1. Remove the 2 bolts and frame.

       HINT:

       Remove the frame through the service hole.

       NOTE: Be careful when removing the bolts as the frame may fall and become damaged.
       Fig 19: Removing Frame Through Service Hole

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. REMOVE DOOR OUTSIDE HANDLE COVER ASSY 
    1. Remove the hole plug.
    2. Using a Torx socket wrench (T30), loosen the screw and remove the cover with the door lock key cylinder installed.
       Fig 20: Removing Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. REMOVE FRONT DOOR LOCK ASSY LH 
    1. Disconnect the door lock connector.
    2. w/o Door closer:

       Using a Torx socket wrench (T30), remove the 3 screws and door lock.

    3. w/ Door closer:

       Using a Torx socket wrench (T30), remove the 5 screws and door lock.

       HINT:

       Remove the door lock through the service hole.

       NOTE: Be careful when removing the bolts as the door lock may fall and become damaged.
    4. Remove the door remote control cable and door inside locking cable.
       Fig 21: Removing Door Remote Control Cable And Door Inside Locking Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Disconnect the connector.
    2. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
    3. Remove the outside handle pad front and rear.
       NOTE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.
       Fig 22: Removing Outside Handle Pad Front And Rear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Remove the nut.
    2. Slide the outside handle frame to remove it.
    3. Remove the nut and outside handle frame.
       NOTE: Be careful when removing the bolts as the frame may fall and become damaged.

       HINT:

       Remove the frame through the service hole.

       Fig 23: Removing Frame Through Service Hole

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. REMOVE FRONT DOOR CHECK ASSY LH 
    1. Remove the cover.
    2. Remove the bolt, 2 nuts and door check.
       NOTE: Be careful when removing the bolts as the door check may fall and become damaged.

       HINT:

       Remove the door check through the service hole.

       Fig 24: Removing Door Check Through Service Hole

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

       HINT:

       If clips are damaged during removal, replace them.

25. INSTALL FRONT DOOR CHECK ASSY LH 
    1. Apply MP grease to the sliding areas of the door check.
    2. Install the door check to the door panel with the 2 nuts.

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

    3. Apply adhesive to the threads of the bolt.

       Adhesive: 

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

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

       Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) 

    5. Install the cover.
       Fig 25: Installing Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Install the lock open rod to the outside handle frame.
    2. Install the frame with the nut.

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

       NOTE: A cover should be inserted between the nut and the door panel.
       Fig 26: Installing Frame With Nut

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Install the outside handle pad front and rear.
    2. Pull and hold the release plate of the frame as shown in the illustration.
       Fig 27: Installing Outside Handle Pad Front And Rear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the handle by pushing it in the direction indicated by the arrow marks in the illustration.
       NOTE: If the release plate is not pulled and held when installing the handle, the release plate will Interfere with the handle and become damaged.
       Fig 28: Installing Handle

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL FRONT DOOR LOCK ASSY LH 
    1. Apply MP grease to the sliding and rotating areas of the door lock.
       Fig 29: Installing Front Door Lock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply adhesive to the threads of the 3 screws.

       Adhesive: 

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

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

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

    4. w/ Door closer:

       Using a Torx socket wrench (T30), install the 2 screws.

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

    5. Connect the door lock connector.
       Fig 30: Connecting Door Lock Connector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. INSTALL DOOR OUTSIDE HANDLE COVER ASSY 
    1. Using a Torx socket wrench (T30), install the outside handle cover with the screw.

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

    2. Install the hole plug.
       Fig 31: Installing Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. INSTALL FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH 
    1. Install the frame with the 2 bolts.

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

       Fig 32: Installing Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
31. INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER LH
    1. Install the frame with the 2 bolts.

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

       Fig 33: Installing Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
32. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH FRONT 
    1. Align the matchmarks. Keep them aligned until the window glass installation is complete.
       Fig 34: Aligning Matchmarks

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a Torx driver (T25), install the motor with the 3 screws.

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

       Fig 35: Installing Motor

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Apply MP grease to the sliding and rotating areas of the window regulator.
       NOTE: Do not apply grease to the spring of the window regulate
       Fig 36: Installing Front Door Window Regulator Sub-Assy LH

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

       Torque: 11 N.m (115 kgf.cm, ft.lbf) 

       Fig 37: Installing Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. INSTALL FRONT DOOR GLASS SUB-ASSY LH 
    1. Insert the door glass into the door panel along the glass run as indicated by the arrow mark in the illustration.
       Fig 38: Installing Front Door Glass Sub-Assy LH

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

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

       Fig 39: Installing Door Glass To Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. INSTALL FRONT DOOR GLASS RUN LH 
    1. Using a hand riveter or an air riveter, install the glass run to the door with the 5 rivets.
       Fig 40: Installing Glass Run To Door

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       • Do not prize the riveter. The riveter will be damaged and the mandrel will bend.
         Fig 41: Identifying Incorrect Position

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • Do not tilt the riveter when fastening the rivet to the glass run as this will cause the rivet to be loose.
       • Do not have any space between the rivet head and the glass run. The rivet head must be completely flat against the glass run.
         Fig 42: Identifying Rivet Position

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • Do not have any space between the glass runs. Firmly hold together the two items while installing the rivet.
    2. Connect the speaker connector.
       Fig 43: Connecting Speaker Connector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. INSTALL OUTER REAR VIEW MIRROR ASSY LH 
    1. Install the mirror with the 3 bolts.

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

    2. Connect the mirror connector.
       Fig 44: Connecting Mirror Connector

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
37. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door as shown in the illustration.
    2. Install a new service hole cover.

       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, check the sealing quality.
    3. Connect the 2 connectors and install the wire.
    4. Install the door electrical key oscillator with 2 screws.
       Fig 45: Installing Door Electrical Key Oscillator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
38. INITIALIZE POWER WINDOW SYSTEM (see  INITIALIZATION  )