LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2004 >> RX 330 FWD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Front Door (Exterior Body Panels) >> Overhaul

Front Door (Exterior Body Panels): Overhaul

HINT:

  1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY 
    1. Using a screwdriver, disengage the 2 claws and 2 clips, and disconnect the master switch.

      HINT:

      Tape the screwdriver tip before use.

    2. Disconnect the master switch connector.
    3. Remove the 3 screws and master switch.
      Fig 1: Disconnecting Master Switch Connector
      G03479346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
    1. Using a screwdriver, disengage the 2 clips and claw, and remove the lower frame bracket garnish.

    HINT:

    Tape the screwdriver tip before use.

    Fig 2: Removing Lower Frame Bracket Garnish (LH)
    G03479347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH 
    1. Using a screwdriver, disengage the 3 claws and remove the inside handle bezel.

    HINT:

    Tape the screwdriver tip before use.

    Fig 3: Removing Front Door Inside Handle Bezel Plug (LH)
    G03479348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
    1. Remove the door armrest cover.
    2. Remove the 2 screws and clip A indicated in the illustration.
    3. Using a screwdriver, disengage other 11 clips.
    4. Remove the trim board.

      HINT:

      • In order to prevent the door panel from being damaged, cover the areas indicated by arrow marks in the illustration with protective tape.
      • Tape the screwdriver tip before use.
    5. Disconnect the 2 cables from the inside handle.
    6. Disengage the connectors and remove the trim board.
      Fig 4: Removing Trim Board
      G03479349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a screwdriver, disengage the claw and, remove the lamp in the direction indicated by arrow marks in the illustration.

    HINT:

    Tape the screwdriver tip before use.

    Fig 5: Removing Lamp
    G03479350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH 
    1. Remove the weatherstrip inner by pulling it upward in the direction indicated by arrow mark in the illustration.
      Fig 6: Removing Weatherstrip Inner (LH)
      G03479351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
    1. Disconnect the mirror connector.
    2. Remove the 3 bolts and mirror.
    NOTE: When the nuts are removed, the mirror may fall and become deformed.
    Fig 7: Removing Mirror Bolt
    G03479352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FRONT DOOR BELT MOULDING ASSY LH (See REPLACEMENT  ) 
  8. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH (See  REPLACEMENT  ) 
  9. REMOVE FRONT DOOR ARMREST SET BRACKET LH 
    1. Remove the 2 screws and armrest set bracket.
  10. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    NOTE: Remove the remaining tape on the door side.
  11. REMOVE FRONT NO.1 SPEAKER ASSY (See  REPLACEMENT  ) 
  12. REMOVE FRONT DOOR GLASS SUB-ASSY LH 

    HINT:

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

    1. Open the door glass until the bolts appear in the service holes.
    2. Remove the 2 bolts holding the door glass to the window regulator.
      Fig 8: Removing Bolt
      G03479353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the door glass in the direction indicated by arrows in the illustration.
      NOTE:
      • Do not damage the door glass.
      • When the bolts are removed, the door glass may fall and become deformed.
    4. Remove the glass run.
      Fig 9: Removing Glass Run
      G03479354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
    1. Disconnect the window regulator connector.
    2. Remove the 6 bolts and window regulator.
    NOTE: When the bolts are removed, the window regulator may fall and become deformed.

    HINT:

    Remove the window regulator through the service hole.

    Fig 10: Removing Bolts And Window Regulator
    G03479355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Place matchmarks on the regulator motor gear and regulator gear.
    2. Using a torx driver (T25), remove the 3 screws and window regulator motor.
  15. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Remove the bolt and frame.

    HINT:

    Remove the frame through the service hole.

    Fig 11: Removing Frame Bolt
    G03479356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DOOR OUTSIDE HANDLE COVER 
    1. Remove the hole plug.
    2. Using a torx socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.
      Fig 12: Removing Front Door Outside Handle Cover
      G03479357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT DOOR LOCK ASSY LH 
    1. Disconnect the lock connector.
    2. Using a torx socket wrench (T30), remove the 3 screws and door lock.

    HINT:

    Remove the door lock through the service hole.

    Fig 13: Removing Front Door Lock Assy (LH)
    G03479358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Pushing and pulling the handle in the direction indicated by arrow mark in the illustration, remove the handle.
    2. Remove the outside handle pads front and rear.
      Fig 14: Removing Handle
      G03479359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a torx socket wrench (T30), loosen the screw.
    2. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration and remove it.

      HINT:

      Remove the outside handle frame through the service hole.

    3. Remove the lock open rod from the outside handle frame.
      Fig 15: Removing Outside Handle Frame (LH)
      G03479360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE FRONT DOOR CHECK ASSY LH 
    1. Remove the check cover.
    2. Remove the 2 nuts, bolt and door check.
      Fig 16: Removing Nut (LH)
      G03479361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a clip remover, disengage the clips and remove the weatherstrip.

    HINT:

    If the clips are damaged, exchange them for new clips.

    Fig 17: Removing Weatherstrip
    G03479362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 N.m (82 kgf.cm, 71 in..lbf) 

      HINT:

      Install the door check so that the rivet head is up.

    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 with the bolt.

      Torque: 27 N.m (275 kgf.cm, 20 in..lbf) 

    5. Install the check cover.
      Fig 18: Installing Door Panel Nut (LH)
      G03479363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Install the lock open rod to the handle frame.
    2. Slide the handle frame in the direction indicated by the arrow mark in the illustration.
    3. Using a torx socket wrench (T30), install the outside handle frame with the screw.

      Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

      NOTE: Insert a cover between the nut and the door panel.
    4. Install the outside handle pads front and rear.
      Fig 19: Installing Front Door Outside Handle Frame Sub-Assy (LH)
      G03479364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. 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.
      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.
    3. Insert the door lock open rod into the door lock and then set it to the door panel.
      NOTE: Make sure that the outside handle link is securely engaged with the door lock.
      Fig 20: Installing Door Lock Wire Harness Packing
      G03479365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Apply adhesive to the threads of the 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, 42 in..lbf) 

    6. Connect the door lock connector.
      Fig 21: Connecting Door Lock Connector
      G03479366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER 
    1. Using a torx socket wrench (T30), install the outside handle cover with the screw.

      Torque: 7.0 N.m (71 kgf.cm, 62 in..lbf) 

    2. Install the hole plug.
      Fig 22: Installing Hole Plug
      G03479367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Install the door frame with the bolt.

    Torque: 5.0 N.m (51 kgf.cm, 42 in..lbf) 

    Fig 23: Installing Door Frame With Bolt
    G03479368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Align the matchmarks on the regulator motor gear and regulator gear.
    2. Using a torx driver (T25), install the regulator motor with the 3 screws.

    Torque: 5.4 Nm (55 kgfcm, 48 in..lbf) 

    HINT:

    Never rotate the motor to the down direction until the window glass installation is done.

  28. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH 
    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 24: Locating Front Door Window Regulator Sub-Assy (LH)
      G03479369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the window regulator with the 6 bolts in the order as shown in the illustration.

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

    3. Connect the window regulator connector.
    NOTE: Be careful not to drop the door window regulator as this may cause deformation.
    Fig 25: Installing Bolts
    G03479370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL FRONT DOOR GLASS SUB-ASSY LH 
    NOTE: Do not damage the door glass.
    1. Install the glass run.
    2. Insert the door glass into the door panel along the glass run in the direction indicated by the arrow mark in the illustration.
      Fig 26: Installing Glass
      G03479371Courtesy 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) 

    4. Reset the power window motor (See step 16) under PRE-CHECK ).
    5. Inspect operation of the power window.

    HINT:

    When the installation point of the door glass does not match, adjust the regulator position in 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 manual operation.
      Fig 27: Installing Bolt
      G03479372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL OUTER REAR VIEW MIRROR ASSY LH
    1. Install the mirror with the 3 bolts.

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

    2. Connect the mirror connector.
      Fig 28: Installing Mirror With Bolts
      G03479373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door panel, as shown in the illustration.
    2. Install the service hole cover.

    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, confirm the sealing condition.
      Fig 29: Applying Butyl Tape
      G03479374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals