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Front Door: Overhaul

NOTE:
  • Installation is in the reverse order of the removal. But the installation is indicated only when it has a point.
  • In the RH side, work in the same procedure as in the LH side.
  1. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSY (W/O POWER WINDOW) 
    1. Using a shop rag, remove the snap ring.
    2. Remove the front door window regulator handle and plate.
      Fig 1: Removing Front Door Window Regulator Handle & Plate
      G02864294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FRONT DOOR PULL HANDLE LH 
    1. Remove the screw.
    2. Using a screwdriver, remove the door pull handle.
    NOTE: Tape the screwdriver tip before use.
    Fig 2: Identifying Front Door Pull Handle LH
    G02864295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY (W/ POWER WINDOW) 
    1. Using a screwdriver, remove the power window regulator master switch assembly from the trim board.
      Fig 3: Removing Power Window Regulator Master Switch Assembly
      G02864296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Tape the screwdriver tip before use.
    2. Disconnect the master switch connector.
    3. Remove the 3 screws and base panel from the master switch.
  4. REMOVE FRONT ARMREST BASE PANEL UPPER LH (W/O POWER WINDOW) 
    1. w/o Power door lock:

      Remove the front armrest base panel upper.

      1. Using a screwdriver, remove the front armrest base panel upper from the trim board.
      NOTE: Tape the screwdriver tip before use.
    2. w/ Power door lock:

      Remove the front armrest base panel upper.

      1. Using a screwdriver, remove the front armrest base panel upper from the trim board.
        NOTE: Tape the screwdriver tip before use.
      2. Disconnect the door lock switch connector.
      3. Remove the door lock switch from the base panel.
  5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
    1. Remove the lower frame bracket garnish.
      2. Fig 4: Removing Front Door Lower Frame Bracket Garnish
      G02864297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
    1. Remove the screw.
    2. Using a screwdriver, disengage the clips and then pull the trim board upward to remove it.
      3. Fig 5: Disengaging Clips & Removing Trim Board
      G02864298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Tape the screwdriver tip before use.
  7. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSY LH 
    1. Remove the inside handle, and then disconnect the 2 cables from the inside handle.
      Fig 6: Removing Front Door Inside Handle Sub-Assy LH
      G02864299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    1. Remove the 6 screws and door trim bracket.
      Fig 7: Removing Front Door Service Hole Cover LH
      G02864300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the service hole cover.
      NOTE: Remove the remaining tape on the body side.
    3. Remove the 2 screws and front door reinforcement.
  9. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
    1. Disconnect the outer mirror connector.
    2. w/o Front No.2 speaker assembly:

      Remove the outer mirror assembly.

      Fig 8: Removing Outer Rear View Mirror Assy
      G02864301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove the 3 nuts and outer mirror assembly.
    3. w/ Front No.2 speaker assembly:

      Remove the outer mirror assembly.

      1. Disconnect the speaker connector.
      2. Remove the 2 nuts and front No.2 speaker.
      3. Remove the nut and outer mirror.
  10. REMOVE FRONT DOOR BELT MOULDING ASSY LH (See  REPLACEMENT  ) 
  11. REMOVE FRONT NO.1 SPEAKER ASSY 
    1. Disconnect the speaker connector.
    2. Using a drill of less than (/) 4 mm (0.16 in.), drill out the rivet heads and remove the speaker.
      3. Fig 9: Drilling Out Rivet Heads To Remove Speaker
      G02864302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Gently and vertically put the drill onto the rivet, and cut the rivet flanges.
      NOTE:
      • Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
      • Be careful with the cut rivet, because it is hot.
    4. Even if the flange is taken off, continue drilling and push out the remaining fragments with the drill.
    5. Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.
  12. REMOVE FRONT DOOR INSIDE PANEL PLATE LH 
    1. Remove the 3 screws and front door inside panel plate.
      Fig 10: Removing Front Door Inside Panel Plate
      G02864303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT DOOR GLASS SUB-ASSY LH 
    NOTE: Insert a shop rag inside the door panel to prevent the glass from being 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.
    Fig 11: Removing Front Door Glass Sub-Assy LH
    G02864304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Pull the glass upward to remove it.
  14. REMOVE FRONT DOOR GLASS RUN LH 
    1. Remove the front door glass run.
  15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH (W/O POWER WINDOW) 
    1. Loosen the 6 bolts.
      NOTE: When the bolts are removed, the front door window regulator might drop and be deformed.
    2. Remove the 6 bolts and front door window regulator.
  16. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH (W/ POWER WINDOW) 
    Fig 12: Removing Front Door Window Regulator Sub-Assy
    G02864305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the window regulator connector.
    2. Loosen the 6 bolts.
      NOTE: When the bolts are removed, the front door window regulator might drop and be deformed.
    3. Remove the 6 bolts and front door window regulator.
  17. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH (W/ POWER WINDOW) 
    1. Place matchmarks on the window regulator motor bracket and regulator gear.
    2. Remove the 3 screws and motor.
  18. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    Fig 13: Removing Front Door Frame Sub-Assy Rear Lower LH
    G02864306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt and front door frame rear lower.
  19. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Remove the hole plug.
    2. Using a Torx wrench (T30), loosen the screw and remove the door outside handle cover with the door lock key cylinder installed.
  20. REMOVE FRONT DOOR LOCK ASSY LH (W/O POWER DOOR LOCK) 
    1. Using a Torx wrench (T30), remove the 3 screws and door lock assembly.
      NOTE: Remove the door lock through the service hole.
    2. Remove the door lock wire harness packing.
      Fig 14: Removing Front Door Outside Handle Cover LH
      G02864307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH (W/ POWER DOOR LOCK) 
    1. Disconnect the power door lock connector.
    2. Using a Torx wrench (T30), remove the 3 screws and the power door lock assembly.
      Fig 15: Removing Power Door Lock Assembly
      G02864308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Remove the door lock through the service hole.
    3. Remove the door lock wire harness packing.
  22. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Pushing the outside handle in the arrow mark direction in the illustration, remove the outside handle.
      Fig 16: Removing Outside Front Door Handle Assy
      G02864309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a Torx wrench (T30), loosen the screw.
    2. Using pliers, disengage the clips and remove the door outside handle frame, as shown in the illustration.
      3. Fig 17: Removing Front Door Outside Handle Frame Sub-Assy
      G02864310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  24. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Remove the door panel side bolt and disconnect the front door check.
    2. Using a screwdriver, remove the weatherstrip.
    NOTE: Tape the screwdriver tip before use.
  25. INSTALL FRONT DOOR WEATHERSTRIP LH 
    1. Install the weatherstrip.
    2. Install the front door check assembly with the door panel side bolt.

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

  26. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a Torx wrench (T30), install the outside handle.

      Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf) 

  27. INSTALL FRONT DOOR LOCK ASSY LH (W/O POWER DOOR LOCK) 
    1. Install a new door lock wire harness packing.
    2. Apply MP grease to the sliding and rotating parts of the door lock.
    3. Apply adhesive to the 3 screws.

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

    4. Using a Torx wrench (T30), install the door lock assembly with the 3 screws.

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

  28. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH (W/ POWER DOOR LOCK) 
    1. Install a new door lock wire harness packing.
      NOTE:
      • If reusing the removed lock with front door motor, the packing in the connecting part should be replaced with a new one.
      • Be careful that no grease and dirt will stick to the packing surface in the connecting part.
      • Reusing the removed packing or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock.
    2. Insert the outside handle link into the lock assembly 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. Apply MP grease to the sliding and rotating parts of the door lock.
    4. Apply adhesive to the 3 screws.

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

    5. Using a Torx wrench (T30), install the front door lock assembly with the 3 screws.
      Fig 18: Installing Front Door Lock Assembly
      G02864311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. Connect the power door lock connector.
  29. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Using a Torx wrench (T30), install the door outside handle cover with the screw.
      Fig 19: Installing Door Outside Handle Cover
      G02864312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf) 

    2. Install the hole plug.
  30. INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Install the front door frame rear lower with the bolt.

      Torque: 6.2 N.m (63 kgf.cm, 55 in.lbf) 

  31. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH (W/ POWER WINDOW) 
    1. Align the matchmarks on the regulator motor bracket and regulator gear.
    2. Install the 3 screws.

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

    NOTE: Never rotate the motor to the down direction until the window glass installation has done.
  32. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH (W/ POWER WINDOW) 
    1. Apply MP grease to the sliding and rotating parts of the window regulator.
      Fig 20: Applying MP Grease To Sliding And Rotating Parts Of Window Regulator (W/Power Window)
      G02864313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not apply grease to the spring of the window regulator.
    2. Apply the window regulator to the 6 regulator installation holes on the front door panel, temporarily install the window regulator with the 6 installation bolts.
    3. Tighten the 6 bolts.

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

    4. Connect the window regulator connector.
  33. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH (W/O POWER WINDOW) 
    1. Apply MP grease to the sliding and rotating parts of the window regulator.
      Fig 21: Applying MP Grease To Sliding & Rotating Parts Of Window Regulator (W/O Power Window)
      G02864314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not apply grease to the spring of the window regulator.
    2. Install the front door window regulator with the 6 bolts.

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

  34. INSTALL FRONT DOOR GLASS SUB-ASSY LH (W/ POWER WINDOW) 
    NOTE: Do not damage the door glass.
    1. Put the door glass in the door panel carefully.
    2. Install the door glass to the window regulator with the 2 bolts.
      Fig 22: Installing Door Glass To Window Regulator
      G02864315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Inspect the power window operation.
    NOTE: When the installation point of the front door glass does not match, adjust the regulator position in the 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 in the manual operation.
  35. INSPECT POWER WINDOW FUNCTION (W/ POWER WINDOW) (See  INSPECTION  ) 
  36. INSTALL FRONT NO.1 SPEAKER ASSY 
    1. Install the front speaker to the door.
    2. Using an air riveter or hand riveter, install the front speaker.
      Fig 23: Installing Front Speaker Using Hand Riveter
      G02864316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not prize a riveter, because the riveter will be damaged, and the mandrel will be bent.
        Fig 24: Identifying Wrong Position Of Riveter (1 Of 3)
        G02864317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not tilt the riveter when removing the rivet, because the materials are not tightened firmly.
        Fig 25: Identifying Wrong Position Of Riveter (2 Of 3)
        G02864318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Install the rivet while attaching the materials, because they are not tightened firmly.
    3. Connect the speaker connector.
      Fig 26: Identifying Wrong Position Of Riveter (3 Of 3)
      G02864319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL OUTER REAR VIEW MIRROR ASSY LH 
    1. w/o Front No.2 speaker assembly:

      Install the outer mirror assembly.

      Fig 27: Installing Outer Mirror Assembly
      G02864320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the outer mirror with the 3 nuts.

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

    2. w/ Front No.2 speaker assembly:

      Install the outer mirror assembly.

      1. Temporarily install the outer mirror with the nut.
      2. Temporarily install the front No.2 speaker with the 2 nuts.
      3. Tighten the 3 nuts.

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

      4. Connect the speaker connector.
    3. Connect the outer mirror connector.
  38. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Install the front door reinforcement with the 6 screws.
    2. Install a new service hole cover to the door panel.
      NOTE:
      • 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.
    3. Install the door trim board bracket with the 2 screws.
      Fig 28: Installing Front Door Service Hole Cover
      G02864321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSY (W/O POWER WINDOW) 
    1. Install the regulator handle with the snap ring.
      2. Fig 29: Installing Plate And Regulator Handle With Snap Ring
      G02864322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: With the door window fully closed, install the plate and regulator handle with the snap ring as shown in the illustration.
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