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Section 104 (Front Door): Overhaul

WARNING: This page is about a different car, the 2004 Toyota Sienna. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
  • On the RH side, use the same procedures as on the LH side.
  1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
    1. Using a screwdriver, disengage the clip and claw and remove the garnish.
    NOTE: Tape the screwdriver tip before use.
    Fig 1: Removing Front Door Lower Frame Bracket Garnish LH
    G03061642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH 
    1. Using a screwdriver, disengage the 3 claws and remove the bezel.
    NOTE: Tape the screwdriver tip before use.
    Fig 2: Removing Front Door Inside Handle Bezel Plug LH
    G03061643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY 
    1. Remove the screw.
    2. Using a screwdriver, disengage the clip and claw, and remove the armrest base panel upper together with the switch.
      NOTE: Tape the screwdriver tip before use.
    3. Disconnect the connector.
    4. Remove the 3 screws and switch from the armrest base panel upper.
    5. Using pliers, remove the 2 pins and armrest.
    Fig 3: Removing Power Window Regulator Master Switch Assy
    G03061644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH 
    1. Remove the 3 screws and back frame plate.
      Fig 4: Removing Front Door Trim Board Sub-Assy LH
      G03061645Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 cushion rubbers.
    3. Remove the 2 screws and the clip A.
    4. Using a screwdriver, disengage the other 9 clips.
      NOTE: Tape the screwdriver tip before use.
    5. Remove the trim board upward.
      NOTE: In order to prevent the door panel from being damaged, cover the areas indicated by arrow marks with protective tape.
      Fig 5: Applying Protective Tape
      G03061646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the 2 cables from the inside handle, as shown.
    7. Using a screwdriver, disengage the 10 hooks and remove the weatherstrip inner.
      NOTE: Tape the screwdriver tip before use.
    8. Remove the 2 screws and inside handle.
    Fig 6: Removing Inside Handle
    G03061647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT DOOR SERVICE HOLE COVER LH 
    1. Remove the screw and reinforcement No. 1.
    2. Remove the service hole cover.
    NOTE: Remove the tape remaining on the door side.
    Fig 7: Removing Front Door Service Hole Cover LH
    G03061648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE OUTER REAR VIEW MIRROR ASSY LH 
    1. Disconnect the connector.
    2. Remove the 3 nuts and mirror.
    NOTE: When the nuts are removed, the mirror assy may fall and become deformed.
    Fig 8: Removing Outer Rear View Mirror Assy LH
    G03061649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE FRONT NO. 1 SPEAKER ASSY (See FRONT NO. 1 SPEAKER) 
  8. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH (See  FRONT DOOR WINDOW FRAME MOULDING REAR LH  ) 
  9. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSY OUTER LH (See  FRONT DOOR GLASS WEATHERSTRIP ASSY OUTER LH  ) 
  10. REMOVE FRONT DOOR GLASS SUB-ASSY LH 
    NOTE: 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 9: Removing Door Glass To Window Regulator
      G03061650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the door glass in the direction indicated by the arrows.
      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 10: Removing Glass From Door
    G03061651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. 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 sub-assy may fall and become deformed.
    NOTE: Remove the window regulator through the service hole.
    Fig 11: Removing Window Regulator
    G03061652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Using a torx driver (T25), remove the 3 screws and window regulator motor.
  13. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Remove the bolt and frame.
    Fig 12: Removing Front Door Frame Sub-Assy Rear Lower LH
    G03061653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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 13: Removing Front Door Outside Handle Cover
    G03061654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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 lock.
    NOTE: Remove the door lock through the service hole.
    Fig 14: Removing Front Door W/Motor Lock Assy LH
    G03061655Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Pushing and pulling the outside handle in the direction indicated by the arrows, remove the outside handle.
    2. Remove the outside handle pads front and rear.
    Fig 15: Removing Front Door Handle Assy Outside LH
    G03061656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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 indicated by the arrows, and remove it.
      NOTE: Remove the outside handle frame through the service hole.
    3. Remove the open rod from the outside handle frame.
    Fig 16: Removing Front Door Outside Handle Frame Sub-Assy LH
    G03061657Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE FRONT DOOR CHECK ASSY LH 
    1. Remove the 2 nuts, bolt and door check.
    Fig 17: Removing Front Door Check Assy LH
    G03061658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT DOOR WEATHERSTRIP LH 
    1. Using a clip remover, disengage the clips and remove the weatherstrip.
    NOTE: If the clips are damaged, replace them with new clips.
  20. REMOVE FRONT DOOR WIRE LH 
    1. Disconnect the wire clips.
    2. Remove the 2 bolts and wire.
    Fig 18: Removing Front Door Wire LH
    G03061659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FRONT DOOR WIRE LH 
    1. Install the 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 does not turn up or is not deformed when installing the wire.
    2. Connect the wire clips.
    Fig 19: Installing Front Door Wire LH
    G03061660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FRONT DOOR CHECK ASSY LH 
    1. Apply MP grease to the sliding area of the door check.
    2. Install the door check to the door panel with the 2 nuts.

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

      Fig 20: Installing Front Door Check Assy LH
      G03061661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: 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: 26 N.m (265 kgf.cm, 19 ft.lbf) 

  23. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH 
    1. Install the open rod to the outside handle frame.
    2. Slide the outside handle frame in the indicated by the arrows.
    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 21: Installing Front Door Outside Handle Frame Sub-Assy LH
    G03061662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH 
    1. Install the outside handle pushing in the direction indicated by the arrows.
    NOTE: If the release plate is not pulled and held when installing the outside handle, it will strike against with the outside handle and become damaged.
    Fig 22: Installing Front Door Handle Assy Outside LH
    G03061663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH 
    1. Apply MP grease to the sliding and area of the door lock.
    2. Install a new door lock wire harness packing to the door lock.
      NOTE:
      • When reusing a door lock that has been removed, replace the packing in the connecting part with new packing.
      • Be careful that no grease or 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 open rod into the 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 23: Inserting Open Rod Into Lock
      G03061664Courtesy 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 lock with the 3 screws.

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

    6. Connect the lock connector.
    Fig 24: Installing Lock Connector
    G03061665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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 25: Installing Front Door Outside Handle Cover
    G03061666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER LH 
    1. Install the frame with the bolt.

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

    Fig 26: Installing Front Door Frame Sub-Assy Rear Lower LH
    G03061667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH 
    1. Using a torx driver (T25), install the regulator motor with the 3 screws.

      Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

    NOTE: Never rotate the motor assy to the down direction until the window glass installation is done.
  29. 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 27: Installing Front Door Window Regulator Sub-Assy LH
      G03061668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the window regulator with 6 bolts.

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

    3. Connect the window regulator connector.
    NOTE: Be careful not to drop deformation the door window regulator as this may cause.
    Fig 28: Connecting Window Regulator Connector
    G03061669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. 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 arrows.
      Fig 29: Installing Front Door Glass Sub-Assy LH
      G03061670Courtesy 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 POWER WINDOW CONTROL SYSTEM (W/ JAM PROTECTION) ).
    5. Inspect operation of the power window.
    NOTE: 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 30: Connecting Power Window Switch To Wire Harness
    G03061671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL OUTER REAR VIEW MIRROR ASSY LH 
    1. Install the mirror with the 3 nuts.

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

    2. Connect the mirror connector.
    Fig 31: Installing Outer Rear View Mirror Assy LH
    G03061672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door panel, as shown.
    2. Install the service hole cover.
    Fig 32: Installing Front Door Service Hole Cover LH
    G03061673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:
    • 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.
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