Front Door: Overhaul

HINT:

• Installation is in the reverse order of removal. However, when there is a special point concerning installation, it is indicated.
• Use the same procedures on the RH side as on the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (see STANDARD BOLT ).

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY 
   1. Using a screwdriver, remove the power window regulator master switch assy then disconnect the connector.

   HINT:

   Tape up the screwdriver tip before use.

   Fig 1: Removing Power Window Regulator Master Switch Assy

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
   1. Using a screwdriver, remove the front door lower frame bracket garnish.

   HINT:

   Tape up the screwdriver tip before use.

   Fig 2: Removing Front Door Lower Frame Bracket Garnish LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH 
   1. Using a screwdriver, remove the front door inside handle bezel plug.

   HINT:

   Tape up the screwdriver tip before use.

   Fig 3: Removing Front Door Inside Handle Bezel Plug LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
   1. Remove the 2 screws.
   2. Using a screwdriver, remove the front door trim board.

      HINT:

      Tape up the screwdriver tip before use.

   3. Remove the inside handle then disconnect the 2 cables from the front door lock assy.
   4. Disconnect the connector.
      Fig 4: Removing Front Door Trim Board Sub-Assy LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
   1. Disconnect each connector and remove the front door service hole cover.
   NOTE: Remove the remained tape on the body side.
6. REMOVE FRONT NO.1 SPEAKER ASSY 
   1. Disconnect the connector.
   2. Remove the 3 bolts and the front No.1 speaker assy.
7. REMOVE FRONT DOOR GLASS SUB-ASSY LH 

   HINT:

   Insert a shop rag inside the door panel so that the glass is not scratched.

   1. Open the door glass until the bolts appear in the service hole.
   2. Remove the 2 bolts and door glass.
   NOTE: Do not damage the door glass.

   HINT:

   Pull the glass upward to remove it.

Fig 5: Removing Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
   1. Disconnect the connector.
   2. Loosen the temporarily installed bolt.
      NOTE: When the temporarily installed bolt is removed, the front door window regulator might drop and be deformed.
   3. Remove the 5 bolts and front door window regulator.
9. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH 
   1. Using a torx wrench (T25), remove the 3 torx screws and the window regulator motor assy.
10. REMOVE FRONT DOOR GLASS RUN LH 
11. REMOVE FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH 
    1. Remove the bolt and the front door frame sub-assy front lower.
12. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Remove the bolt and the front door frame sub-assy rear lower.
13. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Remove the hole plug.
    2. Using a torx wrench (T30), loosen the torx screw and remove the front door outside handle cover with the door lock key cylinder installed.
       Fig 6: Removing Hole Plug

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Disconnect the connector.
    2. Using a torx wrench (T30), remove the 3 torx screws and the front door w/motor lock assy.
15. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Pushing the outside handle in the arrow mark direction in Fig 7, remove the front door outside handle.
       Fig 7: Removing Front Door Handle Assy Outside LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. REMOVE DOOR OUTSIDE HANDLE SUB-ASSY LH 
    1. Using a torx wrench (T30), loosen the torx screw.
    2. Using pliers, disengage the clips and remove the front door outside handle, as shown in Fig 8.
    NOTE: Be sure to remove the outside handle together with the clips, because the clips will be damaged if the clips remain attached to the door panel.
    Fig 8: Removing Door Outside Handle Sub-Assy LH

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a screwdriver, remove the door weatherstrip.

    HINT:

    Tape up the screwdriver tip before use.

18. REMOVE FRONT DOOR WEATHERSTRIP UPPER 
    1. Using a screwdriver, remove the door weatherstrip upper.

    HINT:

    Tape up the screwdriver tip before use.

19. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
    1. Remove the 3 bolts.
    2. Disconnect the connector, then remove the outer rear view mirror assy.
20. REMOVE FRONT DOOR BELT MOULDING ASSY LH (See  FRONT DOOR BELT MOULDING ASSY LH  ) 
21. INSTALL DOOR OUTSIDE HANDLE SUB-ASSY LH 
    1. Using a torx wrench (T30), install the front door outside handle with the torx screw.

       Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf) 

22. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Install a new door lock wire harness packing.
       NOTE:

       • If reusing a door lock that has been removed, replace the packing in the connecting part with a new packing.
       • Be careful that no grease and dirt sticks to the packing surface in the connecting part.
       • Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.
    2. Insert the outside handle link into the lock assy with front 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.
    3. Using a torx wrench (T30), install the front door lock assy with the 3 torx screws.

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

23. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Using a torx wrench (T30), install the front door outside handle cover with the torx screw.

       Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf) 

       Fig 9: Installing Front Door Outside Handle Cover LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
24. INSTALL FRONT DOOR GLASS RUN LH 
    1. Install a new front door glass run to the door panel.
25. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Apply MP grease to the sliding and rotating parts of the regulator assy.
    2. Using a torx wrench (T25), install the power window regulator motor assy with the 3 torx screw.

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

    3. If the jam protection does not function properly, perform the following procedure.

    HINT:

    It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed.

    1. Remove the power window motor.

       HINT:

       Place the matchmarks on the power window motor and window regulator gear.

    2. Connect the power window motor and power window switch to the wire harness of the vehicle.
    3. Turn the ignition switch to the ON position and operate the power window switch to idle the power window motor in the upper direction for more than 6 rotations or less than 10 rotations (4 seconds or more).
    4. Assemble the power window motor and regulator.

       HINT:

       • The motor should be installed when the regulator arm is in the middle, not around the upper end (more than 50 mm clearance is necessary from the upper end).
       • Align the matchmarks on the power window motor and window regulator gear when installing the power window motor.
       • Assemble the power window regulator and door glass.

    HINT:

    Never rotate the motor in the lower direction until the installation of the window glass is completed.

26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Temporarily install the 5 bolts to the window regulator sub-assy.
    2. Using the pre-installed 5 bolts, temporarily install the window regulator sub-assy to the front door panel.
    3. Tighten the 5 bolts and the temporarily installed bolt.

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

    4. Connect the connector.
27. INSTALL FRONT DOOR GLASS SUB-ASSY LH 
    1. Install the front door glass with the 2 bolts.

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

    HINT:

    When the installation point of the front door glass does not match, adjust the regulator position by 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 manually.
    3. Check if AUTO UP/AUTO DOWN function operates in the automatic operation.

    HINT:

    • Note that the jam protection function does not operate just after resetting.
    • Reset the regulator again when performing the reverse operation after fully closing the window by AUTO UP operation.
28. INSPECT POWER WINDOW FUNCTION (See  ON-VEHICLE INSPECTION  ) 
29. INSTALL OUTER REAR VIEW MIRROR ASSY RH 
    1. Connect the outer rear view mirror connector.
    2. Install the outer rear view mirror with the 3 bolts.

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

30. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Install a new service hole cover to the door panel.

    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, sealing condition should be confirmed.
      Fig 10: Installing Service Hole Cover LH To Door Panel

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002