Operation CHARM: Car repair manuals for everyone.
Home >> Lexus >> 2005 >> SC 430 V8-4.3L (3UZ-FE) >> Repair and Diagnosis >> Body and Frame >> Doors, Hood and Trunk >> Doors >> Front Door >> Service and Repair

Front Door: Service and Repair

Front Door:






OVERHAUL

HINT:
- Before adjusting the door position for vehicles equipped with side airbags, be sure to disconnect the cable from the negative (-) battery terminal. After adjustment, inspect the SRS warning lamp, the side airbag system for normal operation.
- 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.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.





2. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
a. Using a screwdriver, detach the clip and claw and remove the front armrest assembly.

HINT: Tape the screwdriver tip before use.

b. Remove the 3 screws and power window regulator master switch.

NOTE: Be careful when removing the 3 screws as the switch may fall and become damaged.




3. REMOVE DOOR INSIDE HANDLE BEZEL NO.2 LH
a. Using a screwdriver, detach the 3 claws and remove the door inside handle bezel.

HINT: Tape the screwdriver tip before use.




4. REMOVE FRONT DOOR WINDOW UPPER BRACKET GARNISH LH
a. Using the screwdriver, detach the 2 claws and clip and remove the upper bracket garnish.

HINT: Tape the screwdriver tip before use.




5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the 8 screws.
b. Using a clip remover, remove the 2 clips.
c. Using a screwdriver, detach the 3 clips and remove the door panel.

HINT: Tape the screwdriver tip before use.

d. Disconnect the 2 cables from the inside handle.
e. Remove the door trim board.

6. REMOVE DOOR SIDE AIRBAG SENSOR
7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
8. REMOVE MULTIPLEX NETWORK DOOR ECU FRONT LH
a. Remove the 2 screws and door ECU.

9. REMOVE FRONT DOOR WEATHERSTRIP NO. 2
a. Remove the 2 clips and weatherstrip.




10. REMOVE FRONT DOOR SERVICE HOLE COVER LH
a. Remove the service hole cover.

NOTE: Remove the remaining tape on the door.

11. REMOVE FRONT DOOR SERVICE HOLE COVER NO. 2
a. Remove the 4 screws and service hole cover.




12. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using the clip remover, remove the 4 clips.
b. Using a screwdriver, detach the 21 clips and remove the door weatherstrip.

HINT: Tape the screwdriver tip before use.

13. REMOVE FRONT DOOR BELT MOULDING LH




14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH

HINT: Insert a cushion inside the door panel to prevent scratching the glass.

a. Drivers side:
Temporarily install the window regulator master switch.
b. Passengers side:
Temporarily install the window regulator switch.
c. Move the door glass until the 3 nuts appear in the service holes.
d. Remove the 3 nuts and door glass.

NOTE: Be careful when removing the 3 nuts as the door glass may fall and become damaged.

HINT: Remove the glass upward.

e. Drivers side:
Remove the window regulator master switch.
f. Passengers side:
Remove the window regulator switch.




15. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH
a. Remove the 2 bolts and lower door frame.

HINT: Remove the frame upward.




16. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY LH
a. Disconnect the connector.
b. Remove the 7 nuts and window regulator.

HINT: Remove the window regulator through the service hole.

NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.




17. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT
a. Remove the 2 screws and cover.




b. Using needle nose pliers, remove the drum and wire guide from the motor.

NOTE: Do not use a screwdriver to remove them. Using a screwdriver may damage the regulator wire.




18. REMOVE DOOR OUTSIDE HANDLE COVER ASSEMBLY
a. Remove the hole plug.
b. Using a T30 torx(R) wrench, loosen the screw and remove the cover with the door lock key cylinder installed.

19. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Disconnect the connector.
b. Disconnect the links from the outside handle frame.
c. Using a T30 torx(R) wrench, remove the 4 screws and lock.




20. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
b. Remove the outside handle pad front and rear.

NOTE: If the bellcrank lever is not pulled and held when removing the handle, the bellcrank lever will interfere with the handle and become damaged.




21. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Remove the nut and outside handle frame.
b. Slide the outside handle frame to remove it.

HINT: Remove the frame through the service hole.

c. Remove the lock open rod from the outside handle frame.

22. REMOVE STEREO COMPONENT SPEAKER ASSEMBLY
23. REMOVE DOOR GLASS FEMALE STABILIZER LH
a. Remove the 2 screws and glass female stabilizer.




24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Install the lock open rod to the outside handle frame.
b. Install the frame with the nut.

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

NOTE: A cover should be inserted between the nut and the door panel.




25. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Install the outside handle pad front and rear.
b. Pull and hold the bellcrank lever of the frame as shown in the illustration.




c. Install the handle by pushing it in the direction of the arrow marks in the illustration.

NOTE: If the bellcrank lever is not pulled and held when installing the handle, the bellcrank lever will interfere with the handle and become damaged.

26. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Using a T30 torx(R) wrench, install the door lock with the 4 screws.

Torque: 5.5 N.m (56 kgf.cm, 48 in.lbf)

b. Connect the link to the outside handle.
c. Connect the connector.




27. INSTALL DOOR OUTSIDE HANDLE COVER ASSEMBLY
a. Using a T30 torx(R) wrench, install the cover (with the door lock key cylinder installed) with the screw.

Torque: 7.0 N.m (77 kgf.cm, 62 in.lbf)

b. Install the hole plug.




28. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT
a. Apply MP grease to the sliding and rotating areas of the power window regulator.




b. Apply MP grease to the sliding and rotating areas of the motor.




c. With the holding tool installed, match the holding tool with the motor housing.
d. Push down on the wire guide and drum, and insert the drum into the motor housing.

NOTE: If you cannot insert the drum into the motor, slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.




e. Install the cover plate with the 2 screws.




29. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the window regulator.

NOTE: Do not apply grease to the spring of the front door window regulator.




b. Install the front door window regulator with the 7 nuts.

Torque:
5.5 N.m (56 kgf.cm, 48 in.lbf) for motor side
8.0 N.m (82 kgf.cm, 71 in.lbf) for upper side
13.0 N.m (133 kgf.cm, 10 ft.lbf) for lower side

c. Initialize the power window control system.
1. Drivers side:
Temporarily install the window regulator master switch.
2. Passengers side:
Temporarily install the window regulator switch.
3. Turn the ignition switch ON.
4. Fully close the door glass by manual operation.




5. Using a Dia. 2 mm (0.079 in.) round bar, keep the reset switch pressed.
6. Fully open the door glass by manual operation with the reset switch pressed.
7. Remove the round bar from the reset switch and then fully close the door glass by manual operation.
8. Check if AUTO UP -> AUTO DOWN operates.

CAUTION: Be careful as the jam protection function does not operate just after the initialization is performed.

9. After closing the window fully by AUTO UP operation, initialize the regulator again when performing the reverse operation.
10. Check that the power window functions.
11. Drivers side:
Remove the window regulator master switch.
12. Passengers side:
Remove the window regulator switch.







30. INSPECT FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Check that the clearance measurements of areas A to E are within the standard range.

NOTE: Be careful that the circle-marked weatherstrip marked areas by circles in the illustration are not cut during door glass adjustment.




31. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Adjust the upper end of the front door glass horizontally.
1. Loosen the 2 nuts at the bottom of the window regulator and the nut of the front door mirror bracket.
2. Adjust the fitting of the front door glass at the upper end in the horizontal direction by turning the stud bolt with a 4 mm hexagon wrench.

HINT: When the stud bolt is loosened, the upper end of the glass leans to the inside of the vehicle. When the stud bolt is tightened, the upper end leans to the outside.

3. Tighten the 2 nuts after adjustment.

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




b. Adjust the at the bottom of the front door glass horizontally.
1. Loosen the 2 nuts.
2. Adjust the fitting at the bottom of the front door glass in the horizontal direction.
3. Tighten the 2 nuts after adjustment.

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




c. Adjust the slant of the front door glass (when fully closed)in the up/down direction and in the front/rear direction.
1. Loosen the installation bolts for the front door glass stopper, and install the glass temporarily at the upper end.
2. Loosen the 3 installation nuts for the front door glass.
3. By operating the power window regulator master switch assembly, stop the front door glass at approximately 3 mm (0.118 in.) before the fully closed position.
4. Adjust the slant of the front door glass in the up/down direction and in the front/rear direction while holding up the glass.




5. While holding the front door glass in the fully closed position, press it lightly toward the front door glass stopper and then tighten the bolts and nuts properly.

Torque: 11.5 N.m (117 kgf.cm, 8.5 ft.lbf)

d. Initialize the power window control system.
1. Drivers side:
Temporarily install the window regulator master switch.
2. Passengers side:
Temporarily install the window regulator switch.
3. Turn the ignition switch ON.
4. Fully close the door glass by manual operation.




5. Using a round bar Dia. 2 mm (0.079 in.) round bar,keep the reset switch pressed.
6. Fully open the door glass by manual operation with the reset switch pressed.
7. Remove the round bar from the reset switch and then fully close the door glass by manual operation.
8. Check if AUTO UP -> AUTO DOWN operates.

CAUTION: Be careful the jam protection function does not operate just after the initialization is performed.

9. After closing the window fully by AUTO UP operation, initialize the regulator again when performing the reverse operation.
10. Check that the power window functions.
11. Drivers side:
Remove the window regulator master switch.
12. Passengers side:
Remove the window regulator switch.




32. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Install the 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.

33. INSTALL DOOR SIDE AIRBAG SENSOR
34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
35. PERFORM INITIALIZATION [1][2]Initialization

NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
pro multis · About Operation CHARM