Front Door: Overhaul

WARNING: This page is about a different car, the 2006 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.

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 FRONT DOOR LOWER FRAME BRACKET GARNISH LH
1. Using a screwdriver, remove the lower frame bracket garnish.
HINT:

Tape the screwdriver tip before use.

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

Tape the screwdriver tip before use.

Fig 2: Removing Front Door Inside Handle Bezel LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT ARMREST ASSY LH
1. Disengage the claws, and remove the armrest from the trim board.
HINT:

Tape the screwdriver tip before use.

Fig 3: Removing Front Armrest Assy LH
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH
1. Remove the 2 cushion rubbers.
2. Remove the 2 screws and clips.
3. Using a clip remover, remove the 11 clips.
4. Remove the trim board upward.
  HINT:
  
  In order to prevent the door from being damaged, cover the parts indicated by arrow marks with tape.
  
  Fig 4: Covering Parts Indicated By Arrow Marks With Tape
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the 2 cables from the inside handle as shown.
6. Remove the inner weatherstrip.
7. Remove the 3 screws and power window master switch.
8. Using a screwdriver, disengage the 4 claws.
  HINT:
  
  Tape the screwdriver tip before use.
9. Remove the power mirror switch as shown.
  
  Fig 6: Removing Power Mirror Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR SERVICE HOLE COVER LH
NOTE: Remove the remaining tape on the door side.

Fig 7: Removing Remaining Tape On Door Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTER REAR VIEW MIRROR ASSY LH
1. Disconnect the outer rear view mirror connector.
2. Remove the 3 nuts and outer rear view mirror.
  NOTE: When the nuts are removed, the outer rear view mirror might drop and be deformed.
  
  Fig 8: Removing Nuts & Outer Rear View Mirror
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO.1 SPEAKER ASSY (See FRONT NO.1 SPEAKER ASSY )
REMOVE FRONT NO.2 SPEAKER ASSY
1. Disconnect the speaker connector.
2. Remove the 2 bolts and No. 2 speaker.
3. Remove the 2 bolts and speaker mounting No. 1 bracket.
  
  Fig 9: Removing Bolts & Speaker Mounting No. 1 Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR WINDOW FRAME MOLDING REAR LH (See FRONT DOOR WINDOW FRAME MOLDING REAR LH )
REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSY OUTER LH (See FRONT DOOR GLASS WEATHERSTRIP ASSY OUTER LH )
REMOVE FRONT DOOR GLASS SUB-ASSY LH
HINT:

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 holes.
2. Remove the 2 bolts and holding the door glass.
3. Remove the door glass as shown.
  NOTE:
  - Do not damage the door glass.
  - When the bolts are removed, the door glass might drop and be deformed.
4. Remove the door glass run.
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 might drop and be deformed.
  
  HINT:
  
  Remove the window regulator through the service hole.
  
  Fig 12: Removing Bolts & Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH
1. Place matchmarks on the window regulator motor gear and regulator gear.
2. Using a torx® driver (T25), remove the 3 screws and window regulator motor.
REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH
1. Remove the bolt and frame rear lower.
  
  Fig 13: Removing Bolt & Front Door Frame Sub-Assy Rear Lower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH
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 14: Removing Front Door Outside Handle Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH
1. Disconnect the door 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 15: Removing Screws & Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the door lock wire harness packing.
REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH
1. Pushing and pulling the outside handle in the arrow mark direction, remove the outside handle.
2. Remove the outside handle pad front and rear.
  
  Fig 16: Pulling Outside Handle In Arrow Mark Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 from to remove it.
HINT:

Remove the outside handle frame through the service hole.

Fig 17: Sliding Outside Handle Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DOOR CHECK ASSY LH
1. Remove the 2 nuts, bolt and the door check.
  
  Fig 18: Removing Nuts, Bolt & Door Check
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE FRONT DOOR WIRE LH
1. Disconnect the door wire clips.
2. Remove the 2 bolts and door wire.
  
  Fig 19: Removing Bolts & Door Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR WIRE LH
1. Install the door wire with the 2 bolts.
  Torque reference:
  
  8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  NOTE: In order to prevent water leakage, be sure that the lip of the rubber grommet dose not turn up or is not deformed when installing the door wire.
2. Connect the door wire clips.
INSTALL FRONT DOOR CHECK ASSY LH
1. Apply MP grease to the sliding parts of the door check.
2. Install the door check to the door panel with the 2 nuts.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  Fig 21: Installing Door Check To Door Panel With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply adhesive to the bolt.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
4. Install the door check to the body panel with the bolt.
  Torque: 30 N.m (306 kgf.cm, 22 in.lbf)
  
  HINT:
  
  Install the door check so that rivet head is up.
  
  Fig 22: Installing Door Check To Body Panel With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
1. 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)
2. Install the outside handle pad front and rear.
INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH
1. Apply MP grease to the sliding and rotating parts of the door lock.
2. Install a new door lock wire harness packing.
  NOTE:
  - If reusing the door lock that is removed, replace the packing in the connecting part with a new one.
  - Be careful that no grease and dirt will stick to the packing surface in the connecting part.
  - Reusing the packing that is removed 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.
3. Insert the outside handle link into the lock with the 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.
4. Apply adhesive to the 3 screws.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
  
  Fig 23: Applying Adhesive To Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
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 24: Installing Hole Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 25: Installing Door Frame With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 door regulator motor with the 3 screws.
  Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
  
  HINT:
  
  Never rotate the motor to the down direction until the window glass installation has done.
INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH
1. Apply MP grease to the sliding and rotating parts of the window regulator.
  NOTE: Do not apply grease to the spring of the window regulator.
  
  Fig 26: Applying MP Grease To Sliding & Rotating Parts Of Window Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the window regulator with the 6 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 27: Installing Window Regulator With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the window regulator connector.
  NOTE: Be careful not drop and deform the door window regulator.
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 as shown.
  
  Fig 28: 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 29: Installing Door Glass To Window Regulator With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Inspect operation of the power window.
  HINT:
  
  When the installation point of the 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.
INSTALL FRONT NO.2 SPEAKER ASSY
1. Install the No. 1 speaker bracket with the 2 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
2. Connect the speaker connector.
3. Install the No. 2 speaker with the 2 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
INSTALL OUTER REAR VIEW MIRROR ASSY LH
1. Install the outer rear view mirror with the 3 nuts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf)
  
  Fig 31: Installing Outer Rear View Mirror With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the outer rear view mirror connector.

INSTALL FRONT DOOR SERVICE HOLE COVER LH

Apply butyl tape to the door as shown.
Adhesive:

Part No. 08850-00065, Butyl Tape Set or equivalent

Fig 32: Applying Butyl Tape To Door
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the service hole cover.

SERVICE HOLE DIMENSION SPECIFICATION

A	6 mm (0.236 in.)
B	2 mm (0.079 in.)

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 condition.