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Toyota Corolla (2004+). Manual - part 120

75-19

ENGINE HOOD/DOOR

- REAR DOOR

ADJUST REAR DOOR PANEL SUB-ASSY LH

Body Side

(a) Adjust the door by loosening the body side hinge nuts.

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

B59499

(b) Adjust the door by loosening the door side hinge bolts.

Door Side

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

B59500

(c)

Adjust the striker position by slightly loosening the striker

mounting screws, and hitting the striker with a plastic

hammer.

(d) Tighten the striker mounting screws again.

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

B50237

75-16

ENGINE HOOD/DOOR

- REAR DOOR

REAR DOOR

750DF-02

COMPONENTS

Rear Door Quarter Window Glass LH

Rear Door Outside Handle Assy LH

Rear Door Outside Handle Cover LH

Rear Door Glass

Sub-assy LH

Pad

Rear Door Outside Handle Frame Sub-assy LH

Quarter Window Weatherstrip LH

w/ Power Door Lock

Rear Door Window

Division Bar Sub-assy LH

Rear Door Glass Run LH

Door Lock Wire

Harness Packing

5.0 (51, 44 in.·lbf)

w/o Power Door Lock

Rear Door Lock Assy LH

Door Lock Wire

Harness Packing

6.2 (63, 55 in.·lbf)

Rear Door Belt Moulding Assy LH

5.0 (51, 44 in.·lbf)

26 (265, 19)

Door Hinge

26 (265, 19)

Rear Door Weatherstrip LH

5.5 (56, 49 in.·lbf)

Door Check

N·m (kgf·cm, ft·lbf)

: Specified torque

30 (306, 22)

26 (265, 19)

_ Non-reusable part

F Precoated Part

Door Hinge

B59008

75-17

ENGINE HOOD/DOOR

- REAR DOOR

w/ Power Window

5.4 (55, 48 in.·lbf)

Rear Door Inside Panel Plate LH

8.0 (82, 71 in.·lbf)

Power Window Regulator Motor Assy LH

_ Rear Door Service Hole Cover LH

Rear Door Window Regulator Sub-assy LH

Rear Door Inside Handle Sub-assy LH

8.0 (82, 71 in.·lbf)

Rear Armrest Assy LH

Rear Door Trim Board Sub-assy LH

w/ Power Window

Plate

Snap Ring

Rear Door Window Regulator Handle Assy

Rear Door Armrest Base Panel

Power Window Regulator Switch

N·m (kgf·cm, ft·lbf)

: Specified torque

_ Non-reusable Part

B59007

75-20

ENGINE HOOD/DOOR

- REAR DOOR

750DG-02

OVERHAUL

HINT:

Installation is in the reveres 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.

REMOVE REAR ARMREST ASSY LH

(a) Using a screwdriver, remove the rear armrest.

Clip

HINT:

Tape the screwdriver tip before use.

Clip

: Claw

B59505

REMOVE POWER WINDOW REGULATOR SWITCH

ASSY REAR (W/ POWER WINDOW)

(a) Using a screwdriver, remove the power window regulator

switch assembly.

HINT:

Tape the screwdriver tip before use.

: Claw

B59797

REMOVE REAR DOOR WINDOW REGULATOR

HANDLE ASSY (W/O POWER WINDOW)

(a) Using a shop rag, remove the snap ring.

(b) Remove the rear door window regulator handle and plate.

BO0020

REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH

(a) Remove the 3 screws.

(b) Using a screwdriver, disengage the clips, then pull the

trim board upward to remove it.

HINT:

Tape the screwdriver tip before use.

Clip

B59009

75-21

ENGINE HOOD/DOOR

- REAR DOOR

REMOVE REAR DOOR INSIDE HANDLE SUB-ASSY

(a) Remove the inside handle and then disconnect the 2

cables from the inside handle.

B58050

REMOVE REAR DOOR SERVICE HOLE COVER LH

(a) Disconnect each connector and remove the rear door service hole cover.

NOTICE:

Remove the remaining tape on the body side.

REMOVE REAR DOOR BELT MOULDING ASSY LH (See page 76-13)

REMOVE REAR DOOR GLASS RUN LH

(a) Remove the rear door glass run.

REMOVE REAR DOOR INSIDE PANEL PLATE LH

(a) Remove the 4 screws and rear door inside panel plate.

B59017

10. REMOVE REAR DOOR WINDOW DIVISION BAR

SUB-ASSY LH

(a) Remove the 2 bolts and screw.

(b) Rotate the rear door window division bar by 90° and pull

it upward, as shown in the illustration.

B59021

11. REMOVE REAR DOOR QUARTER WINDOW GLASS LH

(a) Remove the rear door quarter window glass.

NOTICE:

Do not damage the glass.

(b) Remove the quarter window weatherstrip from the glass.

75-22

ENGINE HOOD/DOOR

- REAR DOOR

12. REMOVE REAR 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.

(b) Tilt the door glass and disconnect the roller of the regulator from the channel to remove the door glass.

NOTICE:

Do not damage the door glass.

HINT:

Pull the glass upward to remove it.

13. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY LH (W/O POWER WINDOW)

(a) Loosen the 4 bolts.

NOTICE:

When the bolts are removed, the rear door window regulator might drop and be deformed.

(b)

Remove the 4 bolts and rear door window regulator.

14. REMOVE REAR DOOR WINDOW REGULATOR

SUB-ASSY LH (W/ POWER WINDOW)

(a) Disconnect the window regulator connector.

(b) Loosen the 4 bolts.

NOTICE:

When the bolts are removed, the rear door window regula-

tor might drop and be deformed.

(c)

Remove the 4 bolts and rear door window regulator.

B59022

15.

REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH

(a)

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

16.

REMOVE REAR DOOR LOCK ASSY LH (W/O POWER DOOR LOCK)

(a)

Using a torx wrench (T30), remove the 3 screws and the rear door lock assembly.

17. REMOVE REAR 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.

18. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH

(a) Using a torx wrench (T30), loosen the screw and remove

the rear door outside handle cover.

B59023

19. REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH

(a) Pull and hold the release plate of the outside handle

frame, as shown in the illustration.

B57767

75-23

ENGINE HOOD/DOOR

- REAR DOOR

(b) Pushing the outside handle in the arrow mark direction

as shown in the illustration, remove the outside handle.

NOTICE:

If the release plate is not pulled and held when removing

the outside handle, then the release plate will interfere with

the outside handle and it will damage the release plate.

B56613

20. REMOVE REAR DOOR OUTSIDE HANDLE FRAME

SUB-ASSY LH

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

(b) Using pliers, disengage the clips and remove the 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

B57102

attached to the door panel.

21. REMOVE REAR DOOR WEATHERSTRIP LH

(a) Remove the door panel side bolt and disconnect the rear door check assembly.

(b) Using a screwdriver, remove the weatherstrip.

HINT:

Tape the screwdriver tip before use.

22. INSTALL REAR DOOR WEATHERSTRIP LH

(a) Install the weatherstrip.

(b) Install the rear door check assembly with the door panel side bolt.

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

23. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH

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

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

24. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH

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

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

25. INSTALL REAR 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 lock assembly with the 3 screws.

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

75-24

ENGINE HOOD/DOOR

- REAR DOOR

26. INSTALL REAR DOOR W/MOTOR LOCK ASSY LH (W/

POWER DOOR LOCK)

(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 no grease and dirt will 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) Engage the lock assembly with door motor with the re-

lease plate of the outside handle, and then set it to the

door panel.

NOTICE:

Make sure that the release plate of the outside handle

frame is securely engaged with the lock assembly.

(c)

Apply MP grease to the sliding and rotating parts of the

door lock.

(d) Apply adhesive to the 3 screws.

Part No.08833-00070, THREE BOND 1324 or equiva-

lent

(e) Using a torx wrench (T30), install the door lock assembly

with the 3 screws and bolt.

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

(f)

Connect the power door lock connector.

27. INSTALL POWER WINDOW REGULATOR MOTOR

ASSY LH (W/ POWER WINDOW)

(a) Using a torx wrench (T30), install the power window regu-

lator motor assembly with the 3 screws.

B59023

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

28. INSTALL REAR DOOR WINDOW REGULATOR

w/o Power Window

SUB-ASSY LH (W/O POWER WINDOW)

(a) Apply MP grease to the sliding and rotating parts of the

window regulator.

NOTICE:

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

(b) Install the rear door window regulator with the 4 bolts.

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

B59497

75-25

ENGINE HOOD/DOOR

- REAR DOOR

29. INSTALL REAR DOOR WINDOW REGULATOR

w/ Power Window

SUB-ASSY LH (W/ POWER WINDOW)

(a) Apply MP grease to the sliding and rotating parts of the

window regulator.

NOTICE:

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

(b) Apply the window regulator to the 4 regulator installation

holes on the front door panel, temporarily install the win-

B59498

dow regulator with the installation bolts.

(c)

Tighten the 4 bolts and the temporarily installed bolt.

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

(d) Connect the window regulator connector.

30. INSTALL REAR DOOR WINDOW DIVISION BAR

SUB-ASSY LH

(a) Insert the door window division bar to the door panel, then

rotate it by 90°.

(b) Install the bolt and 3 screws.

(A)

Torque:

Bolt A: 6.2 N·m (63 kgf·cm, 55 in.·lbf)

(A)

B59021

31. INSTALL REAR DOOR GLASS SUB-ASSY LH (W/ POWER WINDOW)

HINT:

Insert a shop rag inside the door panel to prevent the glass from being scratched.

(a) Tilt the door glass and connect the roller of the regulator to the glass channel to install the door glass.

(b) Inspect the power window 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 the manual operation.

(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 operation after closing the window fully in the

AUTO UP operation.

32. INSPECT POWER WINDOW FUNCTION (W/ POWER WINDOW) (See page 70-2)

33. INSTALL REAR 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 after attaching the service hole cover.

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

75-26

ENGINE HOOD/DOOR

- REAR DOOR

34. INSTALL REAR DOOR WINDOW REGULATOR

HANDLE ASSY (W/O POWER WINDOW)

(a) Install the regulator handle with the snap ring.

Front

HINT:

With the door window fully closed, install the plate and regulator

handle with the snap ring as shown in the illustration.

Plate

B58054

76-14

EXTERIOR/INTERIOR TRIM

- BODY ROCKER PANEL MOULDING LH

BODY ROCKER PANEL MOULDING LH

760I0-02

REPLACEMENT

HINT:

Use the same procedures for the RH side and LH side.

REMOVE BODY ROCKER PANEL MOULDING LH

(a) Remove the 8 retainers.

(b) Using a screwdriver, remove the moulding.

Clip

HINT:

Tape the screwdriver tip before use.

(c)

Remove the 7 clips from the moulding.

Retainer

B59781

INSTALL BODY ROCKER PANEL MOULDING LH

(a) Install the moulding with 7 new clips.

New

(b) Install the 8 retainer to the moulding.

Clip

Retainer

B59781

76-12

EXTERIOR/INTERIOR TRIM

- FRONT DOOR BELT MOULDING ASSY LH

FRONT DOOR BELT MOULDING ASSY LH

760I8-02

REPLACEMENT

HINT:

The installation procedures are the removal procedures in reverse order.

Use the same procedures for the RH side and LH side.

REMOVE FRONT ARMREST ASSY LH (See page 75-7)

REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY (W/ POWER WINDOW)

(See page 75-7)

REMOVE FRONT ARMREST BASE PANEL UPPER LH (W/O POWER WINDOW)

(See page 75-7)

REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSY (W/O POWER WINDOW)

(See page 75-7)

REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page 75-7)

REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH (See page 75-7)

REMOVE FRONT DOOR BELT MOULDING ASSY LH

(a) Put protective tape under the weatherstrip.

(b) Using a moulding remover, pry out the weatherstrip as

shown in the illustration.

HINT:

Tape the moulding remover tip before use.

Tape

Moulding Remover

B72676

76-1

EXTERIOR/INTERIOR TRIM

- FRONT BUMPER

FRONT BUMPER

760HX-02

COMPONENTS

Front Bumper Side

Mounting Bracket RH

Front Bumper

Reinforcement

36 (367, 27)

Front Bumper Side

Mounting Bracket LH

36 (367, 27)

5.0 (51, 44 in. lbf)

Radiator Grille

Sub-assy

Front Bumper

Energy Absorber

Front Bumper Cover

w/ Fog Light

Front

Bumper

Hole Cover RH

Front Fog Light

Unit RH

x 4

Retainer

Fog

Front

Light

Spoiler

Front Fog Light

Unit LH

w/ Front Spoiler

Front RH Spoiler Sub-assy

Front Bumper

Front LH Spoiler Sub-assy

Hole Cover LH

Nm (kgfcm, ftlbf)

: Specified torque

B58775

76-2

EXTERIOR/INTERIOR TRIM

- FRONT BUMPER

760HY-02

REPLACEMENT

HINT:

Installation is in the reverse order of the removal. But the installation is indicated only when it has a point.

REMOVE RADIATOR GRILLE SUB-ASSY

(a) Remove the 2 bolts and clip.

(b) Using a screwdriver, remove the radiator grille.

HINT:

Tape the screwdriver tip before use.

B59104

REMOVE FRONT BUMPER COVER

(a) Remove the 6 screws and 2 clips.

Hook

(b) Disengage the hook, and remove the front bumper cover.

(c)

w/ Fog light:

Disconnect the fog light connectors.

REMOVE FRONT BUMPER ENERGY ABSORBER

B59105

REMOVE FRONT BUMPER REINFORCEMENT

(a) Disconnect the wire harness clamp.

(b) Remove the 4 nuts and front bumper reinforcement.

B59112

REMOVE FRONT BUMPER SIDE MOUNTING BRACKET LH

REMOVE FRONT BUMPER SIDE MOUNTING BRACKET RH

REMOVE FRONT LH SPOILER SUB-ASSY (W/ FRONT SPOILER)

(a) Remove the screw and 4 retainers.

(b) Disengage the clip and front LH spoiler.

(c)

Employ the same manner described above to the other side.

REMOVE FRONT RH SPOILER SUB-ASSY (W/ FRONT SPOILER)

REMOVE FOG LIGHT UNIT LH (W/ FOG LIGHT)

(a) Remove the nut and fog light unit.

(b) Employ the same manner described above to the other side.

10. REMOVE FOG LIGHT UNIT RH (W/ FOG LIGHT)

11. REMOVE FRONT BUMPER HOLE COVER LH (W/O FOG LIGHT)

12. REMOVE FRONT BUMPER HOLE COVER RH (W/O FOG LIGHT)

76-3

EXTERIOR/INTERIOR TRIM

- FRONT BUMPER

13. INSTALL FRONT BUMPER REINFORCEMENT

(a) Install the front bumper reinforcement with the 4 nuts.

Torque: 36 N m (367 kgf cm, 27 ft lbf)

B59112

14. INSTALL RADIATOR GRILLE SUB-ASSY

(a) Install the radiator grille with the 2 bolts and clip.

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

B59244

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