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 table (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY
1. Using a screwdriver, remove the front armrest assembly.
HINT:

Fig 1: Removing Front Armrest Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Tape the screwdriver tip before use.
REMOVE DOOR INSIDE HANDLE BEZEL NO. 2 LH
1. Using a screwdriver, remove the door inside handle bezel.
HINT:

Tape the screwdriver tip before use.

Fig 2: Removing Door Inside Handle Bezel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WINDOW UPPER BRACKET GARNISH LH
1. Remove the upper bracket garnish.
Fig 3: Removing Upper Bracket Garnish
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH
1. Remove the 8 screws.
2. Remove the 2 clips.
3. Using a screwdriver, remove the door panel.
  
  Fig 4: Removing Screws, Clips & Door Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
4. Disconnect the 2 cables from the inside handle.
5. Remove the door trim board.
REMOVE OUTER REAR VIEW MIRROR ASSY LH
1. Disconnect the connector.
2. Remove the 3 bolts and the outer rear view mirror assembly.
REMOVE MULTIPLEX NETWORK DOOR ECU FRONT LH
1. Remove the 2 screws and door ECU.
REMOVE FRONT DOOR WEATHERSTRIP NO. 2
1. Remove the 2 clips and weatherstrip No. 2.
REMOVE FRONT DOOR GLASS RUN LH
1. Remove the door glass run.
REMOVE FRONT DOOR SERVICE HOLE COVER LH
1. Remove the service hole cover.
REMOVE FRONT DOOR WEATHERSTRIP LH
1. Using a screwdriver, remove the door weatherstrip.
HINT:

Tape the screwdriver tip before use.

Fig 5: Removing Door Weatherstrip
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR BELT MOLDING LH (See REPLACEMENT )
REMOVE FRONT DOOR SERVICE HOLE COVER NO. 2 LH
1. Remove the 4 screws and door service hole cover No. 2.
REMOVE FRONT DOOR GLASS SUB-ASSY LH
HINT:

Insert a shop rag inside the door panel to prevent scratching the glass.
1. Open the door glass until the bolts appear in the service hole.
2. Remove the 3 nuts and door glass.
Fig 6: Removing 3 Nuts & Door Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Do not damage the door glass.

HINT:

Pull the glass upward to remove it.
REMOVE FRONT DOOR FRAME SUB-ASSY FRONT LOWER LH
1. Remove the 2 bolts and lower door frame.
Fig 7: Removing 2 Bolts & Lower Door Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WINDOW REGULATOR ASSY LH
1. Disconnect the connector.
2. Remove the 7 nuts and window regulator.
Fig 8: Removing Nuts & Window Regulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH
1. Disconnect the connectors.
2. Disconnect the links from the outside handle.
3. Using a torx socket wrench (T30), remove the 4 torx screws and door lock.
APPLICATION BODY GREASE
1. Apply MP grease to the sliding and rotating parts of the regulator assembly and door lock.
REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
1. Using a torx socket wrench, remove the screw and door lock key cylinder.
2. Remove the outside handle from the outside handle frame.
3. Remove the nut and front door outside handle frame.
REMOVE STEREO COMPONENT SPEAKER ASSY
1. Remove the 4 screws and speaker.
REMOVE FRONT NO. 2 SPEAKER ASSY
1. Remove the 2 screws and front speaker.
REMOVE DOOR GLASS FEMALE STABILIZER LH
1. Remove the 2 screws and glass female stabilizer.
INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH
1. Using a torx socket wrench (T30), install the front door lock assembly with the 4 screws.)
  Torque: 5.5 N.m (56 kgf.cm, 48 in.lbf)
2. Connect the link to the outside handle.
3. Connect the connector.
INSTALL FRONT DOOR WINDOW REGULATOR ASSY LH
1. Install the front door window regulator with the 7 nuts.
  Upper side:
  
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Lower side:
  
  Torque: 13.0 N.m (133 kgf.cm, 10 ft.lbf)
  
  Motor side:
  
  Torque: 5.5 N.m (56 kgf.cm, 48 in.lbf)
  
  Fig 10: Installing Front Door Window Regulator With 7 Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the power window regulator and door glass.
3. Connect the power window switch to the wire harness and turn the ignition switch ON.
4. Fully close the door glass by manual operation.
5. By using a round bar (diameter 2 mm) keep the reset switch pressed.
6. Fully open the door glass by manual operation with the reset switch pressed.
7. Take the round bar away from the reset switch and then fully close the door glass by manual operation.
8. Check if AUTO UP --> AUTO DOWN operates in the automatic operation.
  HINT:
  - Note that the jam protection function does not operate just after the reset has done.
  - Reset the regulator again when performing the reverse operation after closing the window fully by AUTO UP operation.
9. Check the power window functions.
INSPECT FRONT DOOR GLASS SUB-ASSY LH
1. Check that the clearance is within the standard value.
Fig 11: Checking Front Door Glass Sub-Assy LH Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
ADJUST FRONT DOOR GLASS SUB-ASSY LH
1. Adjust the fitting of the front door glass at the upper end in the horizontal direction.
  1. Loosen the 2 nuts at the bottom of the window regulator assembly and the nut of the front door mirror bracket.
  2. Adjust the fitting of the front door glass at the upper end in the horizontal direction as shown in Fig 12 , by turning the stud bolt with a hexagon wrench of 2 sides and 4 mm width.
    
    Fig 12: Adjusting Nuts At Bottom Of Window Regulator Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    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.
  3. Tighten the 2 nuts after adjustment.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
2. Adjust the fitting at the bottom of the front door glass LH in the horizontal direction.
  1. Loosen the 2 nuts.
  2. Adjust the fitting at the bottom of the front door glass LH in the horizontal direction as shown in Fig 13 .
  3. Tighten the 2 nuts after adjustment.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 13: Adjusting Nuts At Bottom Of Front Door Glass LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Adjust the slant of the front door glass LH (when fully closed) in the up/down direction and in the front/rear direction.
  1. Loosen the installation bolts for the front door glass stopper, and install the glass temporarily at the upper end.
  2. Loosen the 3 installation nuts for the front door glass LH.
  3. By operating the power window regulator master switch assembly, stop the front door glass LH at approximately 3 mm before the full-closed position.
  4. Adjust the slant of the front door glass LH in the up/down direction and in the front/rear direction as shown in Fig 14 , while holding the glass up.
    
    Fig 14: Adjusting Slant Of Front Door Glass LH In Up/Down & Front/Rear Direction
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. While holding the front door glass LH in the full-closed position, press it lightly toward the front door glass stopper and then tighten the bolts and nuts properly.
  Torque: 11.5 N.m (117 kgf.cm, 8.5 ft.lbf)
  
  Fig 15: Tightening Bolts & Nuts Properly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR SERVICE HOLE COVER LH
1. Install the 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.