front door3.pdf

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75–7
ENGINE HOOD/DOOR
–
FRONT DOOR
750DD–02
OVERHAUL
HINT:
Installation is in the reverse order of the removal. But the installation is indicated only when it has a
point.
In the RH side, work in the same procedure as in the LH side.
1.
REMOVE FRONT ARMREST ASSY LH
Clip
(a)
Using a screwdriver, remove the front armrest.
HINT:
Tape the screwdriver tip before use.
Clip
: Claw
B59502
2.
REMOVE POWER WINDOW REGULATOR MASTER
SWITCH ASSY (W/ POWER WINDOW)
Clip
(a)
Using a screwdriver, remove the power window regulator
master switch assembly from the trim board.
HINT:
Tape the screwdriver tip before use.
(b)
Disconnect the master switch connector.
(c)
Remove the 3 screws and base panel from the master
switch.
: Claw
B59503
3.
REMOVE FRONT ARMREST BASE PANEL UPPER LH
(W/O POWER WINDOW)
w/o Power Door Lock
(a)
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.
(b)
w/ Power door lock:
Remove the front armrest base panel upper.
(1)
: Claw
B59504
Using a screwdriver, remove the front armrest base
panel upper from the trim board.
HINT:
Tape the screwdriver tip before use.
(2)
Disconnect the door lock switch connector.
(3)
Remove the door lock switch from the base panel.
2004 COROLLA (RM1037U)
Author:
Date:
1833
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75–8
ENGINE HOOD/DOOR
–
FRONT DOOR
4.
REMOVE FRONT DOOR WINDOW REGULATOR
HANDLE ASSY (W/O POWER WINDOW)
(a)
Using a shop rag, remove the snap ring.
(b)
Remove the front door window regulator handle and
plate.
BO0020
5.
REMOVE FRONT DOOR LOWER FRAME BRACKET
GARNISH LH
Clip
(a)
Remove the lower frame bracket garnish.
Claw
B58051
6.
REMOVE FRONT DOOR TRIM BOARD SUB–ASSY LH
Clip
(a)
Remove the 3 screws.
(b)
Using a screwdriver, disengage the clips and then pull the
trim board upward to remove it.
HINT:
Tape the screwdriver tip before use.
B59006
7.
REMOVE FRONT DOOR INSIDE HANDLE SUB–ASSY
LH
(a)
Remove the inside handle, and then disconnect the 2
cables from the inside handle.
B58050
8. REMOVE FRONT DOOR SERVICE HOLE COVER LH
(a) Disconnect each connector, and remove the front door service hole cover.
NOTICE:
Remove the remaining tape on the body side.
2004 COROLLA (RM1037U)
Author:
Date:
1834
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75–9
ENGINE HOOD/DOOR
–
FRONT DOOR
9.
REMOVE OUTER REAR VIEW MIRROR ASSY LH
w/o Front No. 2 Speaker Assy
(a)
Disconnect the outer mirror connector.
(b)
w/o Front No. 2 speaker assembly:
Remove the outer mirror assembly.
(1)
Remove the 3 nuts and outer mirror.
(c)
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.
H19808
(3)
Remove the nut and outer mirror.
10.
REMOVE FRONT DOOR BELT MOULDING ASSY LH
(See page 76–12 )
11. REMOVE FRONT NO.1 SPEAKER ASSY
(a) Disconnect the speaker connector.
(b) Using a drill of less than ø 4 mm (0.16 in.), drill out the rivet
heads and remove the speaker.
(c) Gently and vertically put the drill onto the rivet, and cut the
rivet flanges.
NOTICE:
Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.
H19810
Be careful with the cut rivet, because it is hot.
(d)
Even if the flange is taken off, continue drilling and push
out the remaining fragments with the drill.
(e)
Using a vacuum cleaner, remove the drilled rivet and dust
from the inside of the door.
12.
REMOVE FRONT DOOR INSIDE PANEL PLATE LH
(a)
Remove the 3 screws and front door inside panel plate.
B59014
13.
REMOVE FRONT DOOR GLASS SUB–ASSY LH
HINT:
Insert a shop rag inside the door panel to prevent the glass from
being scratched.
(a) Open the door glass until the bolts appear in the service
hole.
(b) Remove the 2 bolts and door glass.
NOTICE:
Do not damage the door glass.
B58052
2004 COROLLA (RM1037U)
Author:
Date:
1835
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75–10
ENGINE HOOD/DOOR
–
FRONT DOOR
HINT:
Pull the glass upward to remove it.
14. REMOVE FRONT DOOR GLASS RUN LH
(a) Remove the front door glass run.
15. REMOVE FRONT DOOR WINDOW REGULATOR SUB–ASSY LH (W/O POWER WINDOW)
(a) Loosen the 6 bolts.
NOTICE:
When the bolts are removed, the front door window regulator might drop and be deformed.
(b)
Remove the 6 bolts and front door window regulator.
16. REMOVE FRONT DOOR WINDOW REGULATOR
SUB–ASSY LH (W/ POWER WINDOW)
(a) Disconnect the window regulator connector.
(b) Loosen the 6 bolts.
NOTICE:
When the bolts are removed, the front door window regula-
tor might drop and be deformed.
(c)
Remove the 6 bolts and front door window regulator.
B59019
17.
REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH (W/ POWER WINDOW)
(a)
Place matchmarks on the window regulator motor bracket and regulator gear.
(b)
Remove the 3 screws and motor.
18.
REMOVE FRONT DOOR FRAME SUB–ASSY REAR
LOWER LH
(a)
Remove the bolt and front door frame rear lower.
B59623
19.
REMOVE FRONT DOOR OUTSIDE HANDLE COVER
LH
(a)
Remove the hole plug.
(b)
Using a torx wrench (T30), loosen the screw and remove
the door outside handle cover with the door lock key cylin-
der installed.
20.
REMOVE FRONT DOOR LOCK ASSY LH (W/O
POWER DOOR LOCK)
(a)
Using a torx wrench (T30), remove the 3 screws and the
door lock assembly.
B56825
2004 COROLLA (RM1037U)
Author:
Date:
1836
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75–11
ENGINE HOOD/DOOR
–
FRONT DOOR
21.
REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH
(W/ POWER DOOR LOCK)
(a)
Disconnect the power door lock connector.
(b)
Using a torx wrench (T30), remove the 3 screws and the
power door lock assembly.
B59020
22.
REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH
(a)
Pushing the outside handle in the arrow mark direction in
the illustration, remove the outside handle.
B56613
23. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME
SUB–ASSY LH
(a) Using a torx wrench (T30), loosen the screw.
Torque: 4.0 N·m (41 kgf·cm, 35 in.·lbf)
(b) Using pliers, disengage the clips and remove the door
outside handle frame, as shown in the illustration.
NOTICE:
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.
B57102
24.
REMOVE FRONT DOOR WEATHERSTRIP LH
(a)
Remove the door panel side bolt and disconnect the front door check assembly.
(b)
Using a screwdriver, remove the weatherstrip.
HINT:
Tape the screwdriver tip before use.
25.
INSTALL FRONT DOOR WEATHERSTRIP LH
(a)
Install the weatherstrip.
(b)
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
(a)
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)
(a)
Apply MP grease to the sliding and rotating parts of the door lock.
(b)
Apply adhesive to the 3 screws.
Part No.08833–00070, THREE BOND 1324 or equivalent
(c)
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)
2004 COROLLA (RM1037U)
Author:
Date:
1837
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