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 chart (see STANDARD BOLT SPECIFICATIONS ).

REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH
1. Using a screwdriver, disengage the 2 clips and remove the garnish.
HINT:

Tape the screwdriver tip before use.

Fig 1: Disengaging 2 Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE BEZEL
1. Using a screwdriver, disengage the 3 claws and remove the plug.
HINT:

Tape the screwdriver tip before use.

Fig 2: Disengaging 3 Claws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DOOR PULL HANDLE
1. Remove the screw and pull handle.
Fig 3: Removing Screw
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT ARMREST BASE PANEL UPPER
1. Driver's side:
  Using a screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel together with the window regulator master switch.
  
  HINT:
  
  Tape the screwdriver tip before use.
2. Disconnect the switch connector.
3. Remove the 3 screws and the window regulator master switch from the armrest base panel upper.
  
  Fig 4: Removing 3 Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Passenger's side:
  Using a screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel together with the 2 switches.
  
  HINT:
  
  Tape the screwdriver tip before use.
5. Disconnect the switch connector.
6. Using a screwdriver, disengage the 2 claws and remove the door control switch.
  
  Fig 5: Disengaging 2 Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Tape the screwdriver tip before use.
7. Using a screwdriver, disengage the 2 claws and remove the power window regulator switch.
  HINT:
  
  Tape the screwdriver tip before use.
REMOVE FRONT DOOR TRIM BOARD SUB-ASSY
1. Remove the screw.
2. Using a screwdriver, disengage the 7 clips and remove the trim board.
  HINT:
  - Tape the screwdriver tip before use.
  - In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration.
  - If the clip cannot be reached with the clip remover, pull on the lower trim to remove it.
  Fig 6: Disengaging 7 Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSY
1. Using a screwdriver, disengage claw A as shown in the illustration.
  HINT:
  
  Tape the screwdriver tip before use.
2. Move the inside handle in the direction indicated by the arrow mark in the illustration. The will release the claw and allow removal of the inside handle.
3. Disconnect the 2 cables from the inside handle.
  
  Fig 7: Disconnecting Cables
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTER REAR VIEW MIRROR ASSY
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 3 Nuts And Mirror
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR SERVICE HOLE COVER
1. Remove the 3 screws and trim bracket.
2. Remove the service hole cover.
  NOTE: Remove the remaining tape on the door side.
3. Remove the 2 screws and service hole cover No. 2.
  
  Fig 9: Removing 3 Screws And Trim Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO.1 SPEAKER ASSY (See REPLACEMENT )
1. Using a drill of less than 4 mm (0.16 in.), drill out the 3 rivet heads and remove the speaker.
  NOTE:
  - Be sure to gently place the drill perpendicularly to the rivet, otherwise the rivet hole and the drill itself will be damaged.
  - Be careful with the cut rivet, because it is hot.
2. Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
3. Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.
Fig 10: Identifying Drill
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR BELT MOULDING
REMOVE FRONT DOOR WINDOW MOULDING REAR
REMOVE DOOR FRAME GARNISH
1. Using a clip remover, disengage the claws and remove the garnish.
Fig 11: Disengaging Claws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR GLASS SUB-ASSY
HINT:

Insert a shop rag inside the door panel to prevent the glass from being scratched.
1. Driver's side:
  Connect the window regulator master switch.
2. Passenger's side:
  Connect the power window regulator switch.
3. Move the door glass until the 2 bolts appear in the service holes.
4. Remove the 2 bolts.
  
  Fig 12: Removing 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Be careful when removing the nuts as the glass may fall and become damaged.
5. Remove the door glass in the direction indicated by the arrow marks in the illustration.
  NOTE: Be careful not to damage the glass.
6. Driver's side:
  Disconnect the window regulator master switch.
7. Passenger's side:
  Disconnect the power window regulator switch.
Fig 13: Removing Door Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY
1. Disconnect the connector.
2. Remove the 6 bolts 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 14: Removing 6 Bolts And Regulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR MOTOR ASSY
1. Using a torx driver (T25), remove the 3 screws and motor.
Fig 15: Removing 3 Screws And Motor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER
1. Remove the bolt and frame.
Fig 16: Removing Bolt And Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE COVER
1. Remove the hole plug.
2. Using a torx socket wrench (T30), loosen the screw and remove the cover with the door lock key cylinder installed.
Fig 17: Identifying Torx Socket Wrench
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE ASSY
1. w/ Smart entry system:
  Disconnect the connector.
2. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
3. Remove the outside handle pad front and rear.
  
  Fig 18: Removing Handle By Sliding And Pulling
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.
REMOVE FRONT DOOR LOCK ASSY
1. Using a torx socket wrench (T30), remove the 3 screws and door lock.
  NOTE: Be careful when removing the bolts as the door lock may fall and become damaged.
  
  HINT:
  
  Remove the door lock through the service hole.
  
  Fig 19: Removing 3 Screws And Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY
1. Remove the 2 screws and stiffener cushion No. 1.
  
  Fig 20: Removing 2 Screws And Stiffener
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a torx socket wrench (T30), loosen the screw of the frame.
  
  Fig 21: Loosening Screw Of Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using pliers, remove the clip and handle frame, as shown in the illustration.
  NOTE: Be sure to remove the outside handle frame together with the clips as the clips will be damaged if they remain attached to the door panel.
  
  HINT:
  
  Remove the frame through the service hole.
  
  Fig 22: Removing Clip And Handle Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR CHECK ASSY
1. Remove the 3 bolts and the door check.
HINT:

Remove the check through the service hole.

Fig 23: Removing 3 Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WEATHERSTRIP
1. Using a clip remover, disengage the clips and remove the weatherstrip.
  HINT:
  
  If clips are damaged during removal, replace them.
INSTALL FRONT DOOR CHECK ASSY
1. Apply MP grease to the sliding areas of the check.
2. Install the check to the door panel with the 2 bolts.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
3. Apply adhesive to the threads of the bolt.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
4. Install the check to the body panel with the bolt.
  Torque: 30 N.m (306 kgf.cm, 22 in.lbf)
Fig 24: Identifying Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY
1. Install the outside handle link.
2. Apply MP grease to the sliding areas of the frame.
3. Using a torx socket wrench (T30), install the frame with the screw.
  Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)
4. Install the stiffener cushion No. 1 with the 2 screws.
Fig 25: Identifying Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE ASSY
1. Install the outside handle pad front and rear.
2. Install the handle by pushing it in the direction of the arrow marks in the illustration.
  NOTE: If the release plate is not pulled and held when installing the handle, the release plate will interfere with the handle and become damaged.
INSTALL FRONT DOOR LOCK ASSY
1. Apply MP grease to the sliding and rotating areas of the door lock.
2. Install a new door lock wire harness packing.
  
  Fig 26: Installing Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - When reinstalling the door lock, always use a new packing.
  - Do not allow grease or dirt which contaminates the gap between the door panel and packing.
  - Old packing or damaged packing cannot effectively protect against water, which can damage the door lock.
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 27: 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)
6. Connect the door lock connector.
  
  Fig 28: Installing Door Lock With 3 Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 29: Identifying Torx Socket Wrench
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER
1. Install the frame with the bolt.
  Torque: 6.2 N.m (63 kgf.cm, 55 in.lbf)
  
  Fig 30: Installing Frame With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR MOTOR ASSY
1. Using a torx driver (T25), install the motor with the 3 screws.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  Fig 31: Installing Motor With 3 Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY
1. Apply MP grease to the sliding and rotating areas of the window regulator.
  NOTE: Do not apply grease to the spring of the window regulator.
  
  Fig 32: Installing Front Door Window Regulator Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosely screw bolt A onto the window regulator.
3. Insert the window regulator into the door panel. Use bolt A to hang the window regulator on the door panel.
4. Install the window regulator with the 5 bolts and tighten bolt A.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  NOTE: Be careful not to drop the window regulator as it may become damaged.
  
  Fig 33: Installing Window Regulator With 5 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the window regulator connector.
INSTALL FRONT DOOR GLASS SUB-ASSY
1. Install the glass run.
  NOTE: Be careful not to damage the glass.
2. Insert the door glass into the door panel along the glass run as indicated by the arrow marks in the illustration.
  
  Fig 34: Inserting Door Glass Into Door Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the door glass to the window regulator with the 2 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 35: Installing Door Glass To Window Regulator With 2 Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 36: Installing Front Speaker
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not prize the riveter. The riveter will be damaged and the mandrel will bend.
    
    Fig 37: Identifying Riveter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not tilt the riveter when fastening the rivet to the speaker as this will cause the rivet to be loose.
  - Do not have any space between the rivet head and the speaker. The rivet head must be completely flat against the speaker.
    
    Fig 38: Identifying Incorrect Position Of Riveter
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not have any space between the speaker and door. Firmly hold together the two items while installing the rivet.
  Fig 39: Connecting Speaker Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the speaker connector.
INSTALL FRONT DOOR SERVICE HOLE COVER
1. Install the service hole cover No. 2 with the 2 screws.
2. Apply butyl tape to the door as shown in the illustration.
3. Install a new service hole cover.
  
  Fig 40: Installing Service Hole Cover No. 2 With 2 Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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, check the sealing quality.
4. Install the trim bracket with the 2 screws.
INSTALL OUTER REAR VIEW MIRROR ASSY
1. Install the mirror with the 2 nuts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
2. Connect the mirror connector.
  
  Fig 41: Connecting Mirror Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INITIALIZE POWER WINDOW SYSTEM (See INITIALIZATION )