Section 926 (Front Door): Overhaul

HINT:

• The installation procedures are the removal procedures in reverse order.
• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.

1. 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: Disengaging Clip & Claw And Removing Garnish

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

      HINT:

      Tape the screwdriver tip before use.

      Fig 2: Removing Front Door Inside Handle Bezel Plug

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT ARMREST BASE PANEL UPPER LH 
   1. Using a screwdriver, disengage the clip and 5 claws, and remove the armrest base panel together with the power window regulator master switch.

      HINT:

      Tape the screwdriver tip before use.

      Fig 3: Removing Armrest Base Panel LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Disconnect the switch connector.
   3. Remove the 3 screws and the power window regulator master switch from the armrest base panel upper.
   4. RH side:

      Using a screwdriver, disengage the clip and 5 claws, and remove the armrest base panel together with the 2 switches.

      HINT:

      Tape the screwdriver tip before use.

      Fig 4: Removing Armrest Base Panel RH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Disconnect the switch connector.
   6. Using a screwdriver, disengage the 2 claws, remove the door control switch assy.

      HINT:

      Tape the screwdriver tip before use.

   7. Using a screwdriver, disengage the 2 claws, remove the power window regulator switch.

      HINT:

      Tape the screwdriver tip before use.

4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
   1. Using a screwdriver, remove the cover.

      HINT:

      Tape the screwdriver tip before use.

   2. Remove the 5 screws as shown in Fig 5 .
      Fig 5: Removing Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using a clip remover, disengage the 8 clips and remove the trim upward.

      HINT:

      If clip cannot be reached with the clip remover, pull on the lower trim to remove it.

      Fig 6: Disengaging Clips & Removing Trim Upward

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Remove the 2 cables.
      Fig 7: Removing Cables

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using a screwdriver, disengage the 11 claws and remove the weatherstrip inner.

      HINT:

      Tape the screwdriver tip before use.

   6. Using a screwdriver, remove the front door trim moulding No. 2 LH.

      HINT:

      Tape the screwdriver tip before use.

5. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
   1. Disconnect the mirror connector.
   2. Remove the 3 nuts and mirror.
      NOTE: Be careful when removing the nuts as the mirror may fall and become damaged. 
      Fig 8: Removing Outer Rear View Mirror Assy LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE FRONT DOOR BELT MOULDING ASSY LH (See  FRONT DOOR BELT MOULDING ASSY LH  ) 
7. REMOVE FRONT NO.1 SPEAKER ASSY (See  FRONT NO.1 SPEAKER ASSY  ) 
8. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
   1. Remove the service hole cover.
      NOTE: Remove the remaining tape on the door side. 
      Fig 9: Removing Service Hole Cover

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE FRONT DOOR GLASS SUB-ASSY LH 
   NOTE: Be careful not to tear the weatherstrip No. 2 while removing the door glass. 

   HINT:

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

   1. Move the door glass until the 3 nuts appear in the service holes.
   2. Remove the 3 nuts.
      NOTE: Be careful when removing the nuts as the glass may fall and become damaged. 
      Fig 10: Removing Nuts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. LH side:

      Connect the switch connector of the power window regulator master switch.

   4. RH side:

      Connect the switch connector of the power regulator window switch.

   5. Move the regulator down enough so that glass assembly can be removed.

      HINT:

      Hold onto the glass to prevent it from falling.

   6. LH side:

      Disconnect the switch connector of power window regulator master switch.

   7. RH side:

      Disconnect the switch connector of power window regulator switch.

      Fig 11: Removing Front Door Glass Sub-Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   8. Move the glass as shown in Fig 12 to remove it.
      NOTE: Be careful not to damage the glass. 
      Fig 12: Removing Glass

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE FRONT DOOR WINDOW REGULATOR ASSY LH 
    1. Disconnect the connector.
    2. Remove the 7 nuts and regulator.
       NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged. 

       HINT:

       Remove the window regulator through the service hole.

       Fig 13: Removing Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 screws and cover.
       Fig 14: Removing Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using needle nose pliers, remove the drum and wire guide from the motor.
       NOTE: Do not use a screwdriver to remove them. Using a screwdriver may damage the regulator wire. 
       Fig 15: Removing Drum & Wire Guide From Motor

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE FRONT DOOR WINDOW STOP UPPER 
    1. Put matchmarks on the window stop and door panel.
       Fig 16: Putting Matchmarks On Window Stop & Door Panel

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and window stop front and rear.
12. REMOVE DOOR GLASS FEMALE STABILIZER LH 
    1. Remove the bolt and stabilizer.
       Fig 17: Removing Door Glass Female Stabilizer LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. REMOVE FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH 
    1. Remove the bolt, nut and frame.

       HINT:

       Remove the frame through the speaker hole.

       Fig 18: Removing Frame Through Speaker Hole

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a clip remover, remove the 2 clips and weatherstrip.
       Fig 19: Removing Clips & Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DOOR OUTSIDE HANDLE COVER 
    1. Remove the hole plug.
       Fig 20: Removing Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a torx socket wrench (T30), loosen the screw and remove the cover with the door lock key cylinder installed.
15. REMOVE FRONT DOOR LOCK ASSY LH 
    1. Disconnect the door lock connector.
    2. Using a torx socket wrench (T30), remove the 3 screws and door lock.
       NOTE: Be careful when removing the bolts as door lock may fall and become damaged. 

       HINT:

       Remove the door lock through the service hole.

       Fig 21: Removing Front Door Lock Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in Fig 22 .
       Fig 22: Removing Handle By Sliding & Pulling

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the outside handle pad front and rear.
       NOTE: If the bellcrank lever is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged. 
    3. Using a torx driver (T30), remove the screw and frame.
       Fig 23: Removing Screw Using Torx Driver (T30)

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

       HINT:

       Remove the door check through the service hole.

       Fig 24: Removing Front Door Check Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a clip remover, remove the 2 clips as shown in Fig 25 .
       Fig 25: Removing Clips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a clip remover, disengage the 21 clips and remove the weatherstrip.

       HINT:

       If clips are damaged during removal, replace them.

19. 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)

       Fig 26: Installing Front Door Check To Door Panel

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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:  26 N.m (265 kgf.cm, 19 ft.lbf)

20. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Using a torx driver (T30), install the frame with the screw.

       Torque:  4.0 N.m (41 kgf.cm, 37 in.lbf)

       Fig 27: Installing Frame Screw Using Torx Driver (T30)

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the outside handle pad front and rear.
    3. Pull and hold the bellcrank lever of the frame as shown in Fig 28 .
       Fig 28: Pulling & Holding Bellcrank Lever

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the handle by pushing it in the direction indicated by the arrow marks in the illustration.
       NOTE: If the bellcrank lever is not pulled and held when installing the handle, the bellcrank lever will interfere with the handle and become damaged. 
21. INSTALL FRONT DOOR LOCK ASSY LH 
    1. Apply MP grease to the sliding and rotating areas of the door lock.
    2. Install a new door lock wire harness packing.
       Fig 29: Installing Front Door Lock Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       NOTE:

       • When reinstalling a door lock, always use new packing. 
       • Do not allow grease or dirt to contaminate the gap between the door panel and packing. 
       • Water will damage the door lock. 
       • Old packing or damaged packing cannot effectively protect against water. 
    3. Insert the control rod into the door lock, and then set it to the door panel.
       NOTE: Make sure that the rod is securely engaged with the lock. 
       Fig 30: Inserting Control Rod Into Door Lock

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 31: Installing Door Lock Screws

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

       Torque:  4.0 N.m (41 kgf.cm, 37 in.lbf)

    2. Install the hole plug.
       Fig 32: Installing Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH 
    1. Install the weatherstrip No. 2 with the 2 clips.
       Fig 33: Installing Weatherstrip With Clips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the frame with the bolt and nut.

       Torque:  5.0 N.m (51 kgf.cm, 44 in.lbf)

       HINT:

       The weatherstrip No. 2 should be positioned as shown in Fig 34 .

       Fig 34: Installing Frame & Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. INSTALL DOOR GLASS FEMALE STABILIZER LH 
    1. Install the stabilizer and bolt.

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

       Fig 35: Installing Stabilizer Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL FRONT DOOR WINDOW STOP UPPER 
    1. Align the matchmarks with the window stop and door panel.
    2. Install the window stop with the bolt.

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

       Fig 36: Installing Window Stop Aligning Matchmarks

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
26. INSTALL FRONT DOOR WINDOW REGULATOR ASSY LH 
    1. Apply MP grease to the sliding and rotating areas of the power window regulator motor.
       Fig 37: Applying MP Grease To Sliding & Rotating Areas

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. With the holding tool installed, match the holding tool with the motor housing.
    3. Push down on the wire guide and drum, and insert the drum into the motor housing.
       NOTE: If you cannot insert the drum into the motor, slowly slide the bracket (see step 26-  f ) for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum. 
       Fig 38: Inserting Drum Into Motor Housing

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the cover plate with the 2 screws.

       Torque:  5.1 N.m (52 kgf.cm, 45 in.lbf)

       Fig 39: Installing Cover Plate

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the power window regulator motor with the window regulator sub-assy.
    6. Apply MP grease to the sliding and rotating parts of the window regulator.
       NOTE: Do not apply grease to the spring of the front door window regulator sub-assy. 
       Fig 40: Applying MP Grease To Sliding & Rotating Parts Of Window Regulator

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the front door regulator sub-assy with the 7 nuts.

       Torque: 

       • 8.0 N.m (82 kgf.cm, 71 in.lbf) 
       • 13 N.m (133 kgf.cm, 9.6 ft.lbf) for A 
       Fig 41: Installing Front Door Regulator Sub-Assy

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
27. INSTALL FRONT DOOR GLASS SUB-ASSY LH 
    NOTE: Be careful not to tear the weatherstrip No. 4 while installing the door glass. 
    1. Insert the glass into the door and put it on the regulator, as shown in Fig 42 .
       Fig 42: Inserting Glass Into Door

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. LH side:

       Connect the switch connector of the power window master switch.

    3. RH side:

       Connect the switch connector of the power window switch.

       Fig 43: Connecting Switch Connector Of Power Window Master Switch

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Move the regulator until the bolts appear in the service hole.
    5. LH side:

       Disconnect the switch connector of the power window master switch.

    6. RH side:

       Disconnect the switch connector of the power window switch.

    7. Install the glass with the 3 bolts.

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

       Fig 44: Installing Glass Bolts

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

    HINT:

    Start the inspection after making sure the front door panel sub-assy is fit properly (see ADJUSTMENT )

    1. Push the window from the inside and make sure that the window is held in place by the roof drip side finish moulding.
    2. Fully close the window, close the door and make sure that the window does not contact the roof drip side finish moulding.
    3. Fully close the window and make sure that the roof drip side finish moulding conceals the window edge.
    4. Close the window and make sure that the window moves up and down smoothly.
    5. Around the window's fully closed position, make sure that the window moves parallel to the roof drip side finish moulding.
    6. Fully close the window. When the window reaches the fully closed position, make sure the front and rear glass side windows stops contact the front and rear window stop uppers simultaneously.

    HINT:

    Check that the clearance is within the reference below when:

    • Closing the door and then fully closing the window.
    • Fully closing the windows and then closing the door.
      Fig 45: Inspecting Front Door Glass Sub-Assy LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Reference: 

    CLEARANCE CHECKING REFERENCE
    
    

    Area	Measurement	Area	Measurement
    A	2.2 mm (0.087 in.)	G	5.5 mm (0.217 in.)
    B	5.9 mm (0.232 in)	H	7.5 mm (0.295 in.)
    C	4.9 mm (0.193 in.)	I	16.8 mm (0.661 in.)
    D	7.4 mm (0.291 in.)	J	9.8 mm (0.386 in.)
    E	15.1 mm (0.594 in.)	K	7.0 mm (0.276 in.)
    F	6.9 mm (0.272 in.)	L	7.5 mm (0.295 in.)

29. ADJUST FRONT DOOR GLASS SUB-ASSY LH 
    1. Loosen the 2 nuts at the bottom of the window regulator.
    2. To adjust the position of the door glass' upper section as indicated by arrows in Fig 46 , turn the stud bolt with a hexagon wrench (2 sides, 4 mm width).

       HINT:

       When the stud bolt is loosened, the upper end of the glass leans to the inside of the vehicle. When the stud bolt is tightened, the upper end leans to the outside.

       Fig 46: Adjusting Front Door Glass Sub-Assy LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 2 nuts after adjustment.

       Torque:  13 N.m (133 kgf.cm, 9.6 ft.lbf)

    4. To further adjust the position of the door glass upper section, use shims.
       1. Loosen the 2 nuts.
       2. Change the number of the installed shims to adjust the bottom of the door glass.
       3. Tighten the 2 nuts after adjustment.

          HINT:

          When less shims are used, the door glass' upper section leans to the inside of the vehicle. When more shims are used, the door glass' upper section leans to the outside of the vehicle.

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

          Fig 47: Adjusting Door Glass & Tightening Nuts

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

          Standard: 

          CLEARANCE SPECIFICATION
          
          

          Shim Size	Part No.	Selection QTY
          1 mm	63277-20030	0 - 4
          2 mm	63277-20050	0 - 2

    5. Adjust the door glass' fully closed position horizontally and vertically, as shown in Fig 48 .
       Fig 48: Adjusting Door Glass Fully Closed

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       1. Loosen the installation 2 bolts for the window stop upper, and install the glass temporarily in the fully closed position.
       2. Loosen the 3 installation nuts for the front door glass.
       3. By operating the power window regulator master switch, stop the door glass at approximately 3 mm before the fully-closed position.
       4. While holding the glass, adjust the door glass' fully closed position in the horizontal and vertical direction, as shown in Fig 49 .
          Fig 49: Adjusting Door Glass Fully Closed Holding Glass

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       5. Tighten the 3 nuts after the adjustment.

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

       6. While holding the door glass in the fully-closed position, press it lightly toward the glass stopper and then tighten the bolts and nuts properly.

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

          Fig 50: Tightening Door Glass In Fully Closed Position

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
30. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door.
    2. Install the service hole cover, as shown in Fig 51 .

       HINT:

       • There should be no wrinkles or folds after attaching the service hole cover.
       • Check if the service hole cover is securely attached.
         Fig 51: Installing Service Hole Cover

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

       Torque:  4.5 N.m (46 kgf.cm, 40 in.lbf)

       Fig 52: Installing Mirror

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector.
32. INITIALIZE POWER WINDOW SYSTEM (See  INITIALIZATION  )