LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2002 >> Corolla LE, Automatic >> Repair and Diagnosis >> Body & Frame >> Exterior/Interior Trim >> Front Door >> Disassembly

Front Door: Disassembly

    NOTE: At the time of assembly, with door window fully closed, install the plate and the regulator handle with the snap ring.
    Fig 1: Identifying Correct Window Regulator Handle Installation Position
    G02146125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Removing Window Regulator Handle (W/O Power Window)
    G02146124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. W/O Power window, 

    Remove regulator handle  :

    Pull off the snap ring with a shop rag and remove the regulator handle and plate.

  2. Remove door inside handle  :
    1. Remove the screw and slide the handle forward.
      Fig 3: Removing Door Handle (Inside Vehicle)
      G02146126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the handle from the control link and remove the handle.
  3. W/Power window, remove power window switch 
  4. Remove armrest panel  .
  5. Remove lower frame bracket garnish  .
  6. Remove outside rear view mirror  .

    Torque: 7.8 N-m (80 kgf.cm, 69 in..lbf)  .

  7. Remove front door trim  :
    1. Remove the clip and 2 screws.
      Fig 4: Locating Front Door Trim Clips & Mounting Screw
      G02146127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. CAUTION: Be careful not to damage the door and door trim.

      Tape the screwdriver tip before use.

    2. Insert a screwdriver between the door and door trim to pry out.
    3. Pull the trim upwards to remove it.
  8. Remove service hole cover  :
      NOTE: At the time of assembly, do not block the grommet sealing with the cover.
    1. Remove the 2 grommets.
      2. NOTE: At the time of assembly, bring out the link through the service hole cover.
    2. Remove the service hole cover.
  9. Remove outside rear view mirror  :
    1. W/Power remote control mirror:

      Disconnect the connector.

    2. Remove the 3 nuts and mirror.
  10. Remove door glass  :
    1. Remove the hole plug.
    2. Remove the 2 bolts and door glass.

      Torque: 8.3 N.m (85 kgf.cm, 74 in. lbf) 

    3. Remove the glass run.
  11. Remove door belt moulding  :
    1. Remove the clip.
      2. NOTE: Tape the scraper tip before use.
      Fig 5: Exploded Side View Of Door Belt Moulding
      G02146128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a scraper, remove the door belt moulding.
  12. Remove service hole plate  :

    Remove the 2 screws and plate.

    13. NOTE: At the time of assembly, using an air riveter, strike rivets into the door frame to install the speaker to the door frame.
    Fig 6: Installing Speaker Rivets
    G02146130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the rivet is not positioned perpendicularly it will bend the mandrel. When the trigger is then pulled, it may damage SST.
    Fig 7: Identifying Mandrel & Example Of Incorrect Rivet Installation
    G02146131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    CAUTION: The cut rivet and rivet cutter will be hot, avoid touching them.
    Do not jiggle the rivet cutter while cutting. You may enlarge the rivet hole or damage the rivet cutter.
    Do not drill the door inner hole.
  13. Remove speaker  :
    1. Using a drill of less then 0 4.8 mm (0.189 in.), drill out the rivet heads and remove the speaker.
      Fig 8: Drilling Speaker Rivets Out
      G02146129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a vacuum cleaner, remove the drilled rivet and the dust from the inside of the door.
  14. Remove lower frame  .
    15. NOTE: Remove the regulator through the service hole.
    At the time or assembly, apply MP grease to the window regulator.
    Do not apply grease to the spring of the window regulator.
    Fig 9: Identifying Service Regulator MP Grease Application Points (Front Door)
    G02146132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Remove window regulator  :
    1. W/Power window, disconnect the connector.
    2. W/Power window, remove the 6 bolts and window regulator.

      Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 

    3. W/O Power window, remove the 5 bolts and window regulator.

      Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 

  16. Remove door lock  :
    Fig 10: Identifying Door Lock Mounting Bolts (Front Door)
    G02146133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the door lock control knob.
    2. Disconnect the control link from the door lock.
    3. Disconnect the links from the outside handle and key cylinder.
    4. W/Power door lock, disconnect the connector.
      5. NOTE: At the time of assembly, apply adhesive to 3 screws.
    5. Remove the 3 screws.

      Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) 

      Adhesive: 

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

      6. NOTE:

      At the time of assembly, apply MP grease to the sliding and rotating parts of the door lock.

      Fig 11: Identifying Door Lock MP Grease Application Points (Front Door)
      G02146134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the door lock through the service hole.
  17. Remove outside handle  :
    1. Remove the 2 bolts and outside handle with key cylinder.

      Torque: 5.4 N.m (55 kgf.cm, 47 in. lbf) 

    2. Remove the bolt and key cylinder from the outside handle.
scientia non olet · About LEMON Manuals