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Front Door: Overhaul

WARNING: This page is about a different car, the 2004 Toyota Corolla. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

  1. REMOVE FRONT ARMREST ASSY LH 
    1. Using a screwdriver, remove the front armrest.

      HINT:

      Tape the screwdriver tip before use.

    Fig 1: Identifying Front Armrest Assy Clips and Claws
    G02898554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. 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.

      HINT:

      Tape the screwdriver tip before use.

    2. Disconnect the master switch connector.
    3. Remove the 3 screws and base panel from the master switch.
    Fig 2: Removing Power Window Regulator Master Switch Assy Clips
    G02898555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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.

      HINT:

      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.
        Fig 3: Removing Front Armrest Base Panel Claws
        G02898556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        Tape the screwdriver tip before use.

      2. Disconnect the door lock switch connector.
      3. Remove the door lock switch from the base panel.
  4. 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 4: Removing Front Door Window Regulator Handle
    G02898557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
    1. Remove the lower frame bracket garnish.
    Fig 5: Identifying Front Door Lower Frame Bracket Garnish Clip
    G02898558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
    1. Remove the 3 screws.
    2. Using a screwdriver, disengage the clips and then pull the trim board upward to remove it.

    HINT:

    Tape the screwdriver tip before use.

    Fig 6: Removing Front Door Trim Board Sub Assy Screws
    G02898559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 7: Identifying Front Door Inside Handle Sub-Assy Cable
    G02898560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    1. Disconnect each connector, and remove the front door service hole cover.
    NOTE: Remove the remaining tape on the body side.
  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.

      1. Remove the 3 nuts and outer mirror.
    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 )
    Fig 8: Identifying Outer Rear View Mirror Nuts Assy LH
    G02898561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT NO.1 SPEAKER ASSY 
    1. Disconnect the speaker connector.
    2. Using a drill of less than 0 4 mm (0.16 in.), drill out the rivet heads and remove the speaker.
    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.
      Fig 9: Removing Front Speaker Assy Rivet Heads
      G02898562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Screws
    G02898563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 hole.
    2. Remove the 2 bolts and door glass.
    NOTE: Do not damage the door glass.
    Fig 11: Removing Front Door Glass Sub-Assy Bolts
    G02898564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    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) 
    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.
    Fig 12: Removing Front Door Window Regulator Bolts
    G02898565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 
    1. Remove the bolt and front door frame rear lower.
    Fig 13: Removing Front Door Frame Rear Lower Bolt
    G02898566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 the door lock assembly.
    Fig 14: Identifying Front Door Outside Handle Cover
    G02898567Courtesy 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 Front Door w/Motor Lock Assy Screws
    G02898568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 Front Door Handle Outside Assy
    G02898569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Using a Torx wrench (T30), loosen the screw.

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

    2. Using pliers, disengage the clips and remove the door outside handle frame, as shown in the illustration.
      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.
    Fig 17: Identifying Front Door Outside Handle Frame Assy
    G02898570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Remove the door panel side bolt and disconnect the front door check assembly.
    2. Using a screwdriver, remove the weatherstrip.

    HINT:

    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. Apply MP grease to the sliding and rotating parts of the door lock.
    2. Apply adhesive to the 3 screws.

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

    3. 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.
      Fig 18: Installing Front Door Lock Assy Bolts
      G02898571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

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

    6. Connect the power door lock connector.
    Fig 19: Installing front door Outside Handle Cover Screws
    G02898572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Using a Torx wrench (T30), install the door outside handle cover with the screw.

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

  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) 

    HINT:

    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.
      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 installation bolts.
    3. Tighten the 6 bolts and the temporarily installed bolt.

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

    4. Connect the window regulator connector.
    Fig 20: Identifying Window Regulators Sliding And Rotating Parts
    G02898573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      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) 

    Fig 21: Locating Sliding and Rotating Parts
    G02898574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 with the 2 bolts to the window regulator.

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

      Fig 22: Installing Front Door Glass Assy Bolts
      G02898575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Inspect the power window operation.

      HINT:

      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.
      3. Check if AUTO UP ?AUTO DOWN operates in the automatic operation.

    HINT:

    • Note that the jam protection function does not operate just after resetting.
    • Reset the regulator again when performing the reverse operation after closing the window fully in the AUTO UP operation.
  35. INSPECT POWER WINDOW FUNCTION (W/ POWER WINDOW) (See  ON-VEHICLE 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 Assy Rivets
      G02898576Courtesy 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 Way of Prizing Riveter
        G02898577Courtesy 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 Way of Tilting Riveter
        G02898578Courtesy 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 Way of Installing Rivet
    G02898579Courtesy 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.
      1. Install the outer mirror with the 3 nuts.

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

      Fig 27: Installing of outer Rear View Mirror Assy Nuts
      G02898580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 a new 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.
    Fig 28: Installing Front Door Service Hole Cover
    G02898581Courtesy 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.

    HINT:

    With the door window fully closed, install the plate and regulator handle with the snap ring as shown in the illustration.

    Fig 29: Installing Front Door Window Regulator Handle
    G02898582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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