Front Door: Service and Repair

FRONT DOOR

Front Door:

Front Door:

Front Door:

REMOVAL

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed below are the LH side.






1. REMOVE DOOR INSIDE HANDLE BEZEL
a. Using a screwdriver, detach the 3 claws and remove the bezel plug.

HINT: Tape the screwdriver tip before use.

2. REMOVE FRONT DOOR TRIM PANEL ASSEMBLY






a. Detach the 2 claws and remove the trim lower cover.
b. Disconnect the connector.






c. Remove the 2 screws.
d. Remove the 13 clips and trim cover.






e. Disconnect the 2 cables from the inside handle.






3. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
a. Remove the 4 screws and inside handle.






4. REMOVE INTERIOR NO. 1 ILLUMINATION LIGHT ASSEMBLY
a. Detach the 2 claws, disconnect the connector and then remove the light.

5. REMOVE FRONT DOOR COURTESY LIGHT ASSEMBLY






a. Detach the 4 claws and remove the lens from the courtesy light.






b. Detach the 2 claws and remove the courtesy light from the door trim panel.
c. Disconnect the connector.






6. REMOVE SEAT MEMORY SWITCH
a. Disconnect the connector.
b. Remove the 2 screws and switch from the door trim panel.






7. REMOVE FRONT NO. 3 DOOR WEATHERSTRIP
a. Remove the 4 clips and weatherstrip from the door.






8. REMOVE FRONT DOOR TRIM COVER
a. Remove the screw.
b. Using a clip remover, detach the 6 clips.






9. REMOVE MULTIPLEX NETWORK SWITCH ASSEMBLY
a. Disconnect the connector.
b. Remove the 3 screws and network switch.






10. REMOVE DOOR FRAME GARNISH
a. Remove the screw.
b. Using a screwdriver, remove the 2 clips and garnish.

HINT: Tape the screwdriver tip before use.

11. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY






12. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER
a. Remove the weatherstrip inner by pulling it upward in the direction indicated the arrows in the illustration.






13. REMOVE MULTIPLEX NETWORK DOOR ECU FRONT
a. Remove the 2 screws and ECU.
b. Disconnect the 3 connectors.






14. REMOVE FRONT DOOR SERVICE HOLE COVER
a. Remove the 2 bolts and door armrest bracket.
b. Remove the service hole cover.

HINT: Remove the remaining tape on the door.

15. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY






a. Driver's side:
Temporarily install the multiplex network master switch.
b. Passenger's side:
Temporarily install the multiplex network switch.
c. Move the door glass until the bolts appear in the service holes.
d. Remove the 2 bolts.

HINT: Be careful when removing the bolts as the glass may fall and become damaged.






e. Remove the door glass in the direction indicated by the arrows in the illustration.

HINT: Remove the glass upward.

NOTICE: Be careful not to damage the glass.

f. Driver's side:
Remove the multiplex network master switch.
g. Passenger's side:
Remove the multiplex network switch.

16. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY
17. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR
18. REMOVE FRONT DOOR WINDOW FRAME MOULDING UPPER






19. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
a. Disconnect the connector.
b. Remove the 6 bolts and window regulator.

HINT: Remove the window regulator through the service hole.

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






20. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY
a. Using a T25 "TORX" driver, remove the 3 screws and motor.

HINT: Be careful when removing the screws as the motor may fall and become damaged.






21. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY
a. Remove the 2 bolts and frame.

HINT: Remove the frame through the service hole.

NOTICE: Be careful when removing the bolts as the frame may fall and become damaged.






22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER
a. Remove the hole plug.
b. Using a T30 "TORX" wrench, loosen the screw and remove the cover with the door lock key cylinder installed.
c. Remove the cylinder from the cover.






23. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE
a. Disconnect the connector.
b. Remove the handle by sliding and pulling it in the direction indicated by the arrow in the illustration.

NOTICE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.

c. Remove the outside handle pad front and rear.






24. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD
a. Detach the 2 claws and remove the pad.






25. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD
a. Detach the 2 claws and remove the pad.






26. REMOVE FRONT DOOR WITH MOTOR LOCK ASSEMBLY
a. Disconnect the door lock connector.
b. Using a T30 "TORX" wrench, remove the 3 screws and door lock.

HINT: Remove the door lock through the service hole.

NOTICE: Be careful when removing the bolts as the door lock may fall and become damaged.

27. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY






a. Detach the connector.
b. Using a T30 "TORX" wrench, loosen the screw.






c. Slide the outside handle frame to remove it.

HINT: Remove the outside handle frame through the service hole.

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






28. REMOVE FRONT NO. 1 DOOR STIFFENER CUSHION
a. Remove the 2 bolts and cushion.






29. REMOVE FRONT DOOR CHECK ASSEMBLY
a. Remove the cover.
b. Remove the bolt, 2 nuts and door check.

HINT: Remove the door check through the service hole.

NOTICE: Be careful when removing the bolts as the door check may fall and become damaged.

30. REMOVE FRONT DOOR WEATHERSTRIP
a. Using a clip remover, detach the clips and remove the weatherstrip.

HINT: If clips are damaged during removal, replace them.






31. REMOVE FRONT DOOR WIRE
a. Disconnect the wire clips.
b. Remove the 2 bolts and door wire.

INSTALLATION

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed below are the LH side.
- A bolt without a torque specification is shown in the standard bolt chart.






1. INSTALL FRONT DOOR WIRE
a. Install the door wire with the 2 bolts.
b. Connect the wire clips.

2. INSTALL FRONT DOOR WEATHERSTRIP
a. Attach the clips to install the weatherstrip.

HINT: If clips are damaged during installation, replace them.






3. INSTALL FRONT DOOR CHECK ASSEMBLY
a. Apply MP grease to the sliding areas of the door check.
b. Install the door check to the door panel with the 2 nuts.

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

c. Apply adhesive to the threads of the bolt.

Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

d. Install the door check to the body panel with the bolt.

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

e. Install the cover.






4. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION
a. Install the cushion with the 2 bolts.

5. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY






a. Install the lock open rod to the outside handle frame.
b. Install the frame with the screw.

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

NOTICE: A cover should be inserted between the screw and the door panel.






c. Connect the connector.






6. INSTALL FRONT DOOR WITH MOTOR LOCK ASSEMBLY
a. Apply adhesive to the threads of the 3 screws.

Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

b. Using a T30 "TORX" wrench, install the door lock with the 3 screws.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

c. Connect the door lock connector.






7. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
a. Attach the 2 claws to install the pad.






8. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
a. Attach the 2 claws to install the pad.

9. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE






a. Pull and hold the bellcrank lever of the frame as shown in the illustration.






b. Install the handle by pushing it in the direction of the arrows in the illustration.

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






10. INSTALL FRONT DOOR OUTSIDE HANDLE COVER
a. Using a T30 "TORX" socket, install the cover (with the door key cylinder) with the screw.

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

b. Install the hole plug.






11. INSTALL FRONT DOOR FRONT LOWER FLAME SUB-ASSEMBLY
a. Install the frame with the 2 bolts.

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






12. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY
a. Apply MP grease to the sliding and rotating areas of the regulator motor.
b. Using a T25 "TORX" driver, install the motor with the 3 screws.

Torque: 5.4 N.m (55 kgf.cm, 49 in.lbf)

13. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY






a. Apply MP grease to the sliding and rotating area of the window regulator.

NOTICE: Do not apply grease to the spring of the window regulator.






b. Loosely install the bolt labeled A onto the window regulator.
c. Insert the window regulator into the door panel. Use the bolt labeled A to hang the window regulator on the door panel.
d. Install the window regulator with the 5 bolts and tighten the bolt labeled A.

Torque: 11.0 N.m (115 kgf.cm, 8 ft.lbf)

NOTICE: Be careful not to drop the window regulator as it may become damaged.

e. Connect the window regulator connector.

14. INSTALL FRONT DOOR WINDOW FRAME MOULDING UPPER
15. INSTALL FRONT DOOR WINDOW FRAME MOULDING REAR
16. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
17. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY






a. Insert the door glass into the door panel along the glass run as indicated by the arrows in the illustration.

NOTICE: Be careful not to damage the glass.






b. Install the door glass to the window regulator with the 2 bolts.

Torque: 5.5 N.m (56 kgf.cm, 49 ft.lbf)






18. INSTALL FRONT DOOR SERVICE HOLE COVER
a. Apply butyl tape to the door as shown in the illustration.
b. Install a new 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, check the sealing quality.

c. Install the door armrest bracket with the 2 bolts.






19. INSTALL MULTIPLEX NETWORK DOOR ECU FRONT
a. Connect the 3 connectors.
b. Install the ECU with the 2 bolts.






20. INSTALL FRONT DOOR GLASS WEATHERSTRIP INNER
a. Install the weatherstrip inner.

21. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY






22. INSTALL DOOR FRAME GARNISH
a. Attach the 2 clips to install the garnish.
b. Install the screw.






23. INSTALL MULTIPLEX NETWORK SWITCH ASSEMBLY
a. Install the network switch with the 3 screws.
b. Connect the connector.






24. INSTALL FRONT DOOR TRIM COVER
a. Install the screw.
b. Attach the 6 clips and install the trim cover.

25. INSTALL FRONT NO. 3 DOOR WEATHERSTRIP
a. Install the weatherstrip to the door with the 4 clips.






26. INSTALL SEAT MEMORY SWITCH
a. Connect the connector.
b. Install the switch to the door trim panel with the 2 screws.

27. INSTALL FRONT DOOR COURTESY LIGHT ASSEMBLY






a. Attach the 2 claws to install the courtesy light to the door trim panel.






b. Attach the 4 claws to install the lens to the courtesy light.






28. INSTALL INTERIOR NO. 1 ILLUMINATION LIGHT ASSEMBLY
a. Connect the connector.
b. Attach the 2 claws to install the light.






29. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
a. Install the inside handle with the 4 screws.

30. INSTALL FRONT DOOR TRIM PANEL ASSEMBLY






a. Connect the 2 cables to the inside handle as shown in the illustration.






b. Attach the 13 clips to install the trim cover with the weatherstrip inner.
c. Install the 2 screws.






d. Connect the connector.
e. Attach the 2 claws to install the trim lower cover.






31. INSTALL DOOR INSIDE HANDLE BEZEL
a. Attach the 3 claws to install the bezel plug.

32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
33. PERFORM INITIALIZATION
a. Perform initialization. [1][2]Programming and Relearning

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

34. CHECK SRS WARNING LIGHT
a. Check the SRS warning light.