Toyota Camry

 XV30 (2002–2006) Service Manual

Engine hood/door
Front door

COMPONENTS

ADJUSTMENT

HINT: On the RH side, use in the same procedure as on the LH side.

HINT: Since the centering bolt is used as a door hinge set bolt, the door can not be adjusted with it on. Substitute a bolt with washer for the centering bolt.

1. INSPECT FRONT DOOR PANEL SUB−ASSY LH

a. Check that the clearance is within the standard value.

2. ADJUST FRONT DOOR PANEL SUB−ASSY LH

1. Using SST, adjust the door by loosening the body side hinge bolts. Forward / rearward and vertically.

2. Tighten the bolts after adjustment.

   Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)

3. Adjust the door by loosening the door side hinge bolts.

   Horizontally and vertically.

4. Tighten the bolts after adjustment.

   Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)

5. Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a brass bar and hammer.

6. Tighten the striker mounting screws after adjustment.

   Torque: 23 N·m (235 kgf·cm, 17 ft·lbf)

OVERHAUL

HINT:

• 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 in the same procedure as on the LH side.

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY

1. Remove the armrest base cover lower.

2. Remove the screw.

3. Using a screwdriver, remove the master switch then disconnect the connector.

HINT: Tape the screwdriver tip before use.

Remove power window regulator master switch assy

2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH

a. Using a screwdriver, remove the lower frame bracket garnish.

HINT: Tape the screwdriver tip before use.

Remove front door lower frame bracket garnish LH

3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH

a. Using a screwdriver, remove the inside handle bezel plug.

HINT: Tape the screwdriver tip before use.

Remove front door inside handle bezel plug LH

4. REMOVE FRONT DOOR TRIM BOARD SUB−ASSY LH

1. Remove the hole plug.

2. Remove the 5 screws.

3. Remove the clip.

4. Using a screwdriver, remove the trim board.

HINT: Tape the screwdriver tip before use.

e. Remove the inside handle then disconnect the 2 cables from the door lock.

Remove front door trim board sub-assy LH

5. REMOVE FRONT DOOR SERVICE HOLE COVER LH

a. Disconnect each connector and remove the service hole cover.

NOTICE: Remove the remaining tape on the body side.

6. REMOVE FRONT No.1 SPEAKER ASSY

1. Disconnect the connector.

2. Remove the 4 bolts and front No.1 speaker.

7. REMOVE FRONT DOOR GLASS SUB−ASSY LH

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

1. Open the door glass until the bolts appear in the service hole.

2.  Remove the 2 bolts and door glass.

NOTICE: Do not damage the door glass.

HINT: Pull the glass upward to remove it.

Remove front door glass sub-assy LH

8. REMOVE FRONT DOOR WINDOW REGULATOR SUB−ASSY LH

1. Disconnect the connector.

2. Loosen the temporarily installed bolt.

NOTICE: When the temporarily installed bolt is removed, the window regulator might drop and be deformed.

c. Remove the 5 bolts and window regulator.

9. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH

a. Using a torx) wrench (T25), remove the 3 screws and the motor assembly.

10. REMOVE FRONT DOOR GLASS RUN LH

11. REMOVE FRONT DOOR FRAME SUB−ASSY FRONT LOWER LH

a. Remove the 2 screws and frame front lower.

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

12. REMOVE FRONT DOOR FRAME SUB−ASSY REAR LOWER LH

a. Remove the screw and frame rear lower.

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

13. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH

1. Remove the hole plug

2.  Using a torx) wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.

Remove front door outside handle cover LH

14. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH

1. Disconnect the connector.

2.  Using a torx) wrench (T30), remove the 3 screws and the door motor.

5. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH

a. Pushing the outside handle in the arrow mark direction in the illustration, remove the outside handle.

Remove front door handle assy outside LH

16. REMOVE DOOR OUTSIDE HANDLE SUB−ASSY LH

1. Using a torx) wrench (T30), loosen the screw.

2. Using pliers, disengage the clips and remove the outside handle, 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.

Remove door outside handle sub-assy LH

17. REMOVE FRONT DOOR WEATHERSTRIP LH

a. Using a screwdriver, remove the door weatherstrip.

HINT: Tape the screwdriver tip before use.

18. REMOVE OUTER REAR VIEW MIRROR ASSY LH

1. Remove the 3 nuts.

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

2. Disconnect the connector then remove the mirror.

19. REMOVE FRONT DOOR BELT MOULDING ASSY LH

20. INSTALL DOOR OUTSIDE HANDLE SUB−ASSY LH

a. Using a torx) wrench (T30), install the handle.

Torque: 4.0 N·m (41 kgf·cm, 37 in.·lbf)

21. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH

a. Install a new door lock wire harness packing.

NOTICE:

• If reusing the removed lock with rear door motor, the packing in the connecting part should be replaced with a new one.

• Be careful that grease and dirt will not 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.

b. Insert the outside handle link into the door lock with front door motor, and then set it to the door panel.

NOTICE: Make sure that the outside handle link is securely engaged with the lock assembly.

3. Apply adhesive to the threads of the 3 screws.

   Adhesive: Part No. 08833−00070, THREE BOND 1324 or equivalent

4. Using a torx) wrench (T30), install the door lock with the 3 screws.

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

22. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH

a. Using a torx) wrench (T30), install the outside handle cover with the screw.

 
Install front door outside handle cover LH

23. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH (W/ JAM PROTECTION)

1.  Apply MP grease to the sliding and rotating parts of the window regulator.

2.  If the jam protection dose not function properly, perform the following procedure.

HINT: It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed.

1. Install the power window motor with the 3 screws.

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

HINT: Place the matchmarks on the power window motor and window regulator gear.

2. Connect the power window motor and power window switch to the wire harness of the vehicle.

3.  Turn the ignition switch ON and operate the power window switch to idle the power window motor in the up side direction for more than 6 rotations or less than 10 rotations (4 seconds or more).

4.  Assemble the power window motor and regulator.

HINT:

• Install the motor when the regulator arm is below the middle point.

• Align the matchmarks on the power window motor and window regulator gear when installing the power window motor.

5. Assemble the power window regulator and door glass.

HINT: Never rotate the motor to the down direction until the installation of the window glass is completed.

24. INSTALL FRONT DOOR WINDOW REGULATOR SUB−ASSY LH

1. Install the temporarily installed bolt securely.

2. Install the temporarily installed bolt to the window regulator to the door panel, and install the front door window regulator temporarily.

3. Tighten the 5 bolts and the temporarily installed bolt.

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

4. Connect the connector.

25. INSTALL FRONT DOOR GLASS SUB−ASSY LH

a. Install the front door glass with the 2 bolts.

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

HINT: When the installation point of the glass does not match, adjust the regulator position by 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 manually.

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 operating after closing the window fully by AUTO UP operation.

26. INSPECT POWER WINDOW FUNCTION

27. INSTALL FRONT DOOR SERVICE HOLE COVER LH

a. 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 on the service hole cover after attaching it.

• After attaching the service hole cover, sealing condition should be confirmed.

 Install front door service hole cover LH

Hood

Rear door

Luggage compartment door

Luggage door hinge torsion bar

Hood support rod

Front door