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 SPECIFIED TORQUE FOR STANDARD BOLTS ).

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

Tape the screwdriver tip before use.

Fig 1: Locating Front Door Lower Frame Bracket Garnish LH Clip And Claw
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR PULL HANDLE
1. Remove the screw, and then remove the handle upward.
  
  Fig 2: Removing Door Pull Handle Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY
1. Using a screwdriver, disengage the clip and claw, and remove the armrest base panel upper together with the switch.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 3: Identifying Power Window Regulator Master Switch Assy Clip And Claw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the switch connector.
3. Remove the 3 screws and the switch from the armrest base panel upper.
  NOTE: Be careful when removing the screw as the master switch may fall and become damaged.
  
  Fig 4: Removing Screws And Switch From Armrest Base Panel Upper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Passenger's side:
  Using a screwdriver, disengage the 2 claws and remove the power window regulator switch.
  
  HINT:
  
  Tape the screwdriver tip before use.
  
  NOTE: Be careful when disengaging the claws as the switch may fall and become damaged.
REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH
1. Remove the screw and clip A as shown in Fig 5.
2. Using a screwdriver, disengage the 7 clips.
  HINT:
  
  Tape the screwdriver tip before use.
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 Fig 5.
4. Using a screwdriver, disengage the claws and remove the weatherstrip inner.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 5: Removing Front Door Trim Board Sub-Assy LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSY LH
1. Using a screwdriver, disengage the claw A as shown in Fig 6.
  HINT:
  
  Tape the screwdriver tip before use.
2. Move the inside handle in the direction indicated by the arrow mark in Fig 6. This will release the claw and allow removal of the inside handle.
3. Disconnect the cable from the inside handle.
  
  Fig 6: Removing Front Door Inside Handle Sub-Assy LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR SERVICE HOLE COVER LH
1. Remove the 2 screws and bracket.
  
  Fig 7: Removing Front Door Service Hole Cover LH Screws And Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the service hole cover.
  NOTE: Remove the remaining tape on the door.
  
  Fig 8: Removing Remaining Tape On Door
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTER REAR VIEW MIRROR ASSY LH (See REPLACEMENT )
REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSY OUTER LH (See REPLACEMENT )
REMOVE FRONT NO. 1 SPEAKER ASSY
1. Using a drill of less than diameter 4 mm (0.16 in.), drill out the 3 rivet heads and remove the speaker.
  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 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 rivet and dust from the inside of the door.
  
  Fig 9: Drilling Out Front No. 1 Speaker Assy Rivet Heads
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR GLASS SUB-ASSY LH
HINT:

Insert a cushion inside the door panel to prevent the glass from being scratched.
1. Driver's side:
  Temporarily install the window regulator master switch.
2. Passenger's side:
  Temporarily instal the power window regulator switch.
3. Move the door glass until the bolts appear in the service holes.
4. 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 10: Removing Bolts Holding Door Glass To Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the door glass in the direction indicated by the arrow marks in Fig 11.
  NOTE: Be careful not to damage the glass.
  
  Fig 11: Removing Door Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the glass run.
7. Driver's side:
  Remove the window regulator master switch.
8. Passenger's side:
  Remove the power window regulator switch.
9. Using a screwdriver, disengage the claw and remove the door window glass clip as indicated by the arrow mark in Fig 12.
  HINT:
  
  Tape the screwdriver tip before use.
  
  Fig 12: Disengaging Claw And Removing Door Window Glass Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 fall and become damaged.
  
  Fig 13: Removing Bolts And Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH
1. Using a Torx driver (T25), remove the 3 screws and motor.
  
  Fig 14: Removing Screws And Motor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH
1. Remove the bolt and frame.
  HINT:
  
  Remove the frame through the service hole.
  
  NOTE: Be careful when removing the bolt as the frame may fall and become damaged.
  
  Fig 15: Removing Bolt And Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR LOCK ASSY LH
1. Disconnect the snap and outside locking link from the outside handle as indicated by the black arrow marks in Fig 16.
2. Disconnect the snap and lock open rod from the outside handle as indicated by the white arrow marks in Fig 16.
  
  Fig 16: Disconnecting Snaps, Outside Locking Link And Lock Open Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Twist the knob and remove it, as shown in Fig 17.
4. Using a screwdriver, disengage the 2 claws and remove the guide.
  HINT:
5. Tape the screwdriver tip before use.
  
  Fig 17: Removing Knob And Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the bolt.
7. Using a Torx socket wrench (T30), remove the 3 screws and door lock.
  HINT:
  
  Remove the door lock through the service hole.
  
  NOTE: Be careful not to drop the window regulator as it may become damaged.
  
  Fig 18: Removing Door Lock Bolts And Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the cable from the lock.
9. Remove the 2 screws and actuator.
  
  Fig 19: Identifying Actuator Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH
1. Remove the 2 bolts and handle together with the cylinder.
  NOTE: Be careful when removing the bolts as the outside handle may fall and become damaged.
  
  Fig 20: Identifying Front Door Handle Assembly Outside LH Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Unlock the cylinder by turning it as indicated by the arrow mark in Fig 21.
  
  Fig 21: Unlocking Cylinder By Turning
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the cylinder.
REMOVE FRONT DOOR CHECK ASSY LH
1. Remove the 3 bolts and door check.
  HINT:
  
  Remove the check through the service hole.
  
  Fig 22: Removing Bolts And Door Check
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
INSTALL FRONT DOOR CHECK ASSY LH
1. Apply MP grease to the sliding areas of the check.
2. Install the check to the door panel with the 2 bolts.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  HINT:
  
  Install the door check so that the rivet head is facing up.
3. Apply adhesive to the threads of the bolt.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
4. Install the check to the body panel with the bolt.
  Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
  
  Fig 23: Installing Front Door Check Assembly LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH
1. Install the cylinder to the handle.
2. Lock the cylinder by turning it as indicated by the arrow mark in Fig 24.
  
  Fig 24: Locking Cylinder By Turning It
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the handle together with the cylinder with the 2 bolts.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  Fig 25: Installing Handle With Cylinder And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR LOCK ASSY LH
1. Install the actuator with the 2 screws.
  
  Fig 26: Identifying Actuator Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply MP grease to the sliding and rotating areas of the door lock.
  
  Fig 27: Identifying Door Lock Areas To Lubricate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bolt.
  Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
4. Apply adhesive to the threads of the 3 screws.
  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, 44 in.lbf)
  
  Fig 28: Installing Door Lock With Adhesive On Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the door lock connector.
7. Install the lock open rod and outside locking link in the direction indicated by the arrow marks in Fig 29.
  
  Fig 29: Installing Lock Open Rod And Outside Locking Link
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Install the guide.
9. Attach the knob as indicated by the white arrow mark in Fig 30.
  HINT:
  
  After attaching the knob, rotate it 90° in the direction indicated by the arrow marks Fig 30.
  
  Fig 30: Installing Guide And Knob
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER LH
1. Install the frame with the bolt.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  Fig 31: Installing Frame With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH
1. Using a Torx driver (T25), install the motor with the 3 screws.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  Fig 32: Installing Motor With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 regulator.
  
  Fig 33: Applying MP Grease To Sliding And Rotating Areas Of Window Regulator
  Courtesy 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)
  
  NOTE: Be careful not to drop the window regulator as it may become damaged.
  
  Fig 34: Installing Window Regulator With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the window regulator connector.

INSTALL FRONT DOOR GLASS SUB-ASSY LH

Install the glass clip as indicated by the arrow mark in Fig 35.

Standard:

INSTALLATION SPECIFICATIONS

Area	Measurement
Lower frame upper end x glass clip	170 +/- 30 mm (6.70 +/- 1.18 in.)

Fig 35: Installing Glass Clip

G03096821

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the glass run.
NOTE: Be careful not to damage the glass.
Insert the door glass into the door panel along the glass run as indicated in Fig 36.

Fig 36: Inserting Door Glass Into Door Panel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the door glass to the window regulator with the 2 bolts.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

Fig 37: Installing Door Glass To Window Regulator With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Check operation of the power window.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Check that the power window control operates normally by performing the power window control switch UP/DOWN operation several times.
If the result is not as specified, check the power window control switch (see PROBLEM SYMPTOMS TABLE )

INSTALL FRONT NO. 1 SPEAKER ASSY
1. Using a hand riveter or an air riveter, install the speaker to the door with 3 rivets.
  
  Fig 38: Installing Speaker To Door With Rivets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not prize the riveter. The riveter will be damaged and the mandrel will bend.
    
    Fig 39: Avoiding Prizing Riveter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not tilt the riveter when fastening the rivet to the speaker as this will cause the rivet to be loose.
  - Do not have any space between the rivet head and the speaker. The rivet head must be completely flat against the speaker.
    
    Fig 40: Fastening Rivet To Speaker
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not have any space between the speaker and door. Firmly hold together the 2 items while installing the rivet.
2. Connect the speaker connector.
INSTALL FRONT DOOR SERVICE HOLE COVER LH
1. Apply butyl tape to the door as shown in Fig 42.
  
  Fig 42: Applying Butyl Tape To Door
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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. Install the bracket with the 2 screws.
  
  Fig 43: Identifying Service Hole Cover Bracket With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002