750DB–02

B50717

Centering Bolt

Standard Bolt

B59002

mm (in.)

A: 4.0 (0.157)

1.5 (0.059)

C: 0.4 (0.016)

1.5 (0.059)

B: 5.7 (0.217)

1.5 (0.059)

A

B

C

B50239

–

ENGINE HOOD/DOOR

HOOD

75–1

1827

Author:

Date:

2004 COROLLA (RM1037U)

HOOD

ADJUSTMENT

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

1.

INSPECT HOOD SUB–ASSY

(a)

Check that the clearance is within the standard value.

2.

ADJUST HOOD SUB–ASSY

(a)

Adjust the hood by loosening the hood side hinge bolts.
Torque: 13 N

⋅

m (133 kgf

⋅

cm, 10 ft

⋅

lbf)

B59029

B50241

75–2

–

ENGINE HOOD/DOOR

HOOD

1828

Author:

Date:

2004 COROLLA (RM1037U)

(b)

Adjust the hood by turning the cushions.

(c)

Adjust the lock by loosening the 3 bolts.
Torque: 7.0 N·m (82 kgf·cm, 71 in.·lbf)

750DC–02

B59005

Front Door Belt Moulding Assy LH

Front Door
Glass Run LH

Front Door Handle Assy Outside LH

Front Door
Outside Handle
Frame Sub–assy LH

Front Door Weatherstrip LH

Non–reusable Part

Door Hinge

Door Check

Door Hinge

26 (265, 19)

26 (265, 19)

5.5 (56, 49 in.·lbf)

4.0 (41, 35 in.·lbf)

6.2 (63, 55 in.·lbf)

8.0 (82, 71 in.·lbf)

8.0 (82, 71 in.·lbf)

8.0 (82, 71 in.·lbf)

Pad

Hole Plug

Rivet

: Specified torque

N·m (kgf·cm, ft·lbf)

Front Door Glass Sub–assy LH

Outer Rear View Mirror Assy LH

Front Door Lower Frame Bracket Garnish LH

Front Door Frame Sub–assy Rear Lower LH

Front Door Outside Handle Cover LH

Front No.1
Speaker Assy

Front No.2
Speaker Assy

w/ Front No. 2 Speaker Assy

30 (306, 22)

–

ENGINE HOOD/DOOR

FRONT DOOR

75–3

1829

Author:

Date:

2004 COROLLA (RM1037U)

FRONT DOOR

COMPONENTS

B59004

w/ Power Door Lock

Power Window
Regulator Master
Switch
Front Armrest Assy LH

Front Door Window Regulator Handle Assy

Front Door Trim Board Sub–assy LH

Front Door Inside
Handle Sub–assy LH

Front Door Service Hole Cover LH

w/ Power Window

Front Armrest Base
Panel Upper LH

w/ Power Window

Front Door Inside Panel Plate LH

Front Door Armrest
Base Panel

5.0 (51, 44 in.·lbf)

5.4 (55, 48 in.·lbf)

5.0 (51, 44 in.·lbf)

8.0 (82, 71 in.·lbf)

: Specified torque

Non–reusable part

N·m (kgf·cm, ft·lbf)

Precoated Part

Door Lock Wire Harness Packing

Power Window Regulator Motor Assy LH

Plate
Snap Ring

Front Door Window Regulator Sub–assy LH

Front Door Lock Assy LH

w/o Power Window

Front Door
Armrest
Base Panel

Door
Lock Switch

8.0 (82, 71 in.·lbf)

w/o Power Door Lock

75–4

–

ENGINE HOOD/DOOR

FRONT DOOR

1830

Author:

Date:

2004 COROLLA (RM1037U)

750DE–02

N03433

Centering Bolt

Standard Bolt

B59010

mm (in.)

A: 5.0 (0.197)

1.5 (0.059)

A

A

B: 5.5 (0.217)

1.5 (0.059)

B

C: 5.7 (0.224)

1.5 (0.059)

C

160 (6.30)

D

D

D – D

B59406

Body Side

–

ENGINE HOOD/DOOR

FRONT DOOR

75–5

1831

Author:

Date:

2004 COROLLA (RM1037U)

ADJUSTMENT

HINT:

In the RH side, work in the same procedure as in the LH
side.

Since the centering bolt is used as a door side hinge bolt,
the door hinge cannot be adjusted with it on. Substitute
the 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

(a)

Using SST, adjust the door by loosening the body side
hinge bolts.
SST

09812–00010

Torque: 26 N

⋅

m (265 kgf

⋅

cm, 19 ft

⋅

lbf)

B59407

Door Side

B50234

75–6

–

ENGINE HOOD/DOOR

FRONT DOOR

1832

Author:

Date:

2004 COROLLA (RM1037U)

(b)

Adjust the door by loosening the door side hinge bolts.
Torque: 26 N

⋅

m (265 kgf

⋅

cm, 19 ft

⋅

lbf)

(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)

750DD–02

B59502

Clip

Clip

: Claw

B59503

Clip

: Claw

B59504

: Claw

w/o Power Door Lock

–

ENGINE HOOD/DOOR

FRONT DOOR

75–7

1833

Author:

Date:

2004 COROLLA (RM1037U)

OVERHAUL

HINT:

S

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

S

In the RH side, work in the same procedure as in the LH side.

1.

REMOVE FRONT ARMREST ASSY LH

(a)

Using a screwdriver, remove the front armrest.

HINT:
Tape the screwdriver tip before use.

2.

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

(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.

3.

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

(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)

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.

BO0020

B58051

Clip

Claw

B59006

Clip

B58050

75–8

–

ENGINE HOOD/DOOR

FRONT DOOR

1834

Author:

Date:

2004 COROLLA (RM1037U)

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.

5.

REMOVE FRONT DOOR LOWER FRAME BRACKET
GARNISH LH

(a)

Remove the lower frame bracket garnish.

6.

REMOVE FRONT DOOR TRIM BOARD SUB–ASSY LH

(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.

7.

REMOVE FRONT DOOR INSIDE HANDLE SUB–ASSY
LH

(a)

Remove the inside handle, and then disconnect the 2
cables from the inside handle.

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.

H19808

w/o Front No. 2 Speaker Assy

H19810

B59014

B58052

–

ENGINE HOOD/DOOR

FRONT DOOR

75–9

1835

Author:

Date:

2004 COROLLA (RM1037U)

9.

REMOVE OUTER REAR VIEW MIRROR ASSY LH

(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.

(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:

S

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

S

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.

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.

B59019

B59623

B56825

75–10

–

ENGINE HOOD/DOOR

FRONT DOOR

1836

Author:

Date:

2004 COROLLA (RM1037U)

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.

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.

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.

B59020

B56613

B57102

–

ENGINE HOOD/DOOR

FRONT DOOR

75–11

1837

Author:

Date:

2004 COROLLA (RM1037U)

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.

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.

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.

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)

B59020

B56614

75–12

–

ENGINE HOOD/DOOR

FRONT DOOR

1838

Author:

Date:

2004 COROLLA (RM1037U)

28.

INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH
(W/ POWER DOOR LOCK)

(a)

Install a new door lock wire harness packing.

NOTICE:

S

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

S

Be careful that no grease and dirt will stick to the
packing surface in the connecting part.

S

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 lock assembly 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.
(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 front door lock as-
sembly with the 3 screws.
Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf)

(f)

Connect the power door lock connector.

29.

INSTALL FRONT DOOR OUTSIDE HANDLE COVER
LH

(a)

Using a torx wrench (T30), install the door outside handle
cover with the screw.
Torque: 4.0 N·m (41 kgf·cm, 35 in.·lbf)

30.

INSTALL FRONT DOOR FRAME SUB–ASSY REAR LOWER LH

(a)

Install the front door frame rear lower with the bolt.
Torque: 6.2 N·m (63 kgf·cm, 55 in.·lbf)

31.

INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH (W/ POWER WINDOW)

(a)

Align the matchmarks on the regulator motor bracket and regulator gear.

(b)

Install the 3 screws.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

HINT:
Never rotate the motor to the down direction until the window glass installation has done.

B59024

B59025

B58052

–

ENGINE HOOD/DOOR

FRONT DOOR

75–13

1839

Author:

Date:

2004 COROLLA (RM1037U)

32.

INSTALL FRONT DOOR WINDOW REGULATOR
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 6 regulator installation
holes on the front door panel, temporarily install the win-
dow regulator with the installation bolts.

(c)

Tighten the 6 bolts and the temporarily installed bolt.
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

(d)

Connect the window regulator connector.

33.

INSTALL FRONT DOOR WINDOW REGULATOR
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 front door window regulator with the 6 bolts.
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

34.

INSTALL FRONT DOOR GLASS SUB–ASSY LH (W/
POWER WINDOW)

NOTICE:
Do not damage the door glass.
(a)

Put the door glass in the door panel carefully.

(b)

Install the door glass with the 2 bolts to the window regula-
tor.
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

(c)

Inspect the power window operation.

HINT:
When the installation point of the front door glass does not
match, adjust the regulator position in the manual operation.

(1)

Connect the power window switch to the wire har-
ness 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:

S

Note that the jam protection function does not operate
just after resetting.

S

Reset the regulator again when performing the reverse
operation after closing the window fully in the AUTO UP
operation.

H19811

H02440

Mandrel

Riveter

H02441

Riveter

Riveter

H02442

Riveter

75–14

–

ENGINE HOOD/DOOR

FRONT DOOR

1840

Author:

Date:

2004 COROLLA (RM1037U)

35.

INSPECT POWER WINDOW FUNCTION (W/ POWER
WINDOW) (See page

70–2

)

36.

INSTALL FRONT NO.1 SPEAKER ASSY

(a)

Install the front speaker to the door.

(b)

Using an air riveter or hand riveter, install the front speak-
er.

NOTICE:

S

Do not prize a riveter, because the riveter will be dam-
aged, and the mandrel will be bent.

S

Do not tilt the riveter when removing the rivet, be-
cause the materials are not tightened firmly.

S

Install the rivet while attaching the materials, be-
cause they are not tightened firmly.

(c)

Connect the speaker connector.

H19808

w/o Front No. 2 Speaker Assy

B59796

Tape

B58054

30

"

5

_

Plate

Front

–

ENGINE HOOD/DOOR

FRONT DOOR

75–15

1841

Author:

Date:

2004 COROLLA (RM1037U)

37.

INSTALL OUTER REAR VIEW MIRROR ASSY LH

(a)

w/o Front No. 2 speaker assembly:
Install the outer mirror assembly.
(1)

Install the outer mirror with the 3 nuts.

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

(b)

w/ Front No. 2 speaker assembly:
Install the outer mirror assembly.
(1)

Temporarily install the outer mirror with the nut.

(2)

Temporarily install the front No. 2 speaker with the
2 nuts.

(3)

Tighten the 3 nuts.

Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
(4)

Connect the speaker connector.

(c)

Connect the outer mirror connector.

38.

INSTALL FRONT DOOR SERVICE HOLE COVER LH

(a)

Install a new service hole cover to the door panel.

HINT:

S

When installing the service hole cover, pull out the links
and connectors through the service hole cover.

S

There should be no wrinkles or folds after attaching the
service hole cover.

S

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

39.

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

(a)

Install the regulator handle with the snap ring.

HINT:
With the door window fully closed, install the plate and regulator
handle with the snap ring as shown in the illustration.

750DF–02

B59008

w/ Power Door Lock

Rear Door Belt Moulding Assy LH

Rear Door Glass Run LH

Rear Door Weatherstrip LH

Rear Door Window
Division Bar Sub–assy LH

Rear Door Quarter Window Glass LH

Quarter Window Weatherstrip LH

Rear Door Glass
Sub–assy LH

Rear Door Lock Assy LH

Rear Door Outside Handle Cover LH

Rear Door Outside Handle Assy LH

Rear Door Outside Handle Frame Sub–assy LH

Precoated Part

Pad

Door Lock Wire
Harness Packing

5.0 (51, 44 in.·lbf)

5.0 (51, 44 in.·lbf)

: Specified torque

Non–reusable part

N·m (kgf·cm, ft·lbf)

w/o Power Door Lock

Door Hinge

Door Check

Door Hinge

26 (265, 19)

26 (265, 19)

5.5 (56, 49 in.·lbf)

30 (306, 22)

26 (265, 19)

6.2 (63, 55 in.·lbf)

Door Lock Wire
Harness Packing

75–16

–

ENGINE HOOD/DOOR

REAR DOOR

1842

Author:

Date:

2004 COROLLA (RM1037U)

REAR DOOR

COMPONENTS

B59007

Rear Armrest Assy LH

w/ Power Window

Power Window Regulator Switch

Rear Door Window Regulator Handle Assy

Rear Door Trim Board Sub–assy LH

Rear Door Inside Handle Sub–assy LH

Rear Door Service Hole Cover LH

w/ Power Window

Rear Door Window Regulator Sub–assy LH

Non–reusable Part

Rear Door Inside Panel Plate LH

Rear Door Armrest Base Panel

: Specified torque

N·m (kgf·cm, ft·lbf)

Power Window Regulator Motor Assy LH

8.0 (82, 71 in.·lbf)

8.0 (82, 71 in.·lbf)

Plate

Snap Ring

5.4 (55, 48 in.·lbf)

–

ENGINE HOOD/DOOR

REAR DOOR

75–17

1843

Author:

Date:

2004 COROLLA (RM1037U)

750DH–02

N03433

Centering Bolt

Standard Bolt

B59011

B

C

A

E

D

E

E

mm (in.)

A: 5.5 (0.217)

1.5 (0.059)

B: 5.6 (0.220)

1.5 (0.059)

C: 5.9 (0.232)

1.5 (0.059)

D: 6.0 (0.236)

1.5 (0.059)

E: 5.0 (0.197)

1.5 (0.059)

42 (1.65)

129 (5.08)

F

F

F–F

G–G

G

G

75–18

–

ENGINE HOOD/DOOR

REAR DOOR

1844

Author:

Date:

2004 COROLLA (RM1037U)

ADJUSTMENT

HINT:

In the RH side, work in the same procedure as in the LH side.

Since the centering bolt is used as a door side hinge bolt,
the door hinge cannot be adjusted with it on. Substitute
the bolt with washer for the centering bolt.

1.

INSPECT REAR DOOR PANEL SUB–ASSY LH

(a)

Check that the clearance is within the standard value.

2.

REMOVE FRONT DOOR SCUFF PLATE LH (See page

76–21

)

3.

REMOVE REAR DOOR SCUFF PLATE LH (See page

76–21

)

4.

REMOVE FRONT DOOR WEATHERSTRIP LH (See page

75–7

)

5.

REMOVE REAR DOOR WEATHERSTRIP LH (See page

75–20

)

6.

REMOVE CENTER PILLAR GARNISH LOWER LH (See page

76–21

)

B59499

Body Side

B59500

Door Side

B50237

–

ENGINE HOOD/DOOR

REAR DOOR

75–19

1845

Author:

Date:

2004 COROLLA (RM1037U)

7.

ADJUST REAR DOOR PANEL SUB–ASSY LH

(a)

Adjust the door by loosening the body side hinge nuts.
Torque: 26 N

⋅

m (265 kgf

⋅

cm, 19 ft

⋅

lbf)

(b)

Adjust the door by loosening the door side hinge bolts.
Torque: 26 N

⋅

m (265 kgf

⋅

cm, 19 ft

⋅

lbf)

(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)

750DG–02

B59505

Clip

Clip

: Claw

B59797

: Claw

BO0020

B59009

Clip

75–20

–

ENGINE HOOD/DOOR

REAR DOOR

1846

Author:

Date:

2004 COROLLA (RM1037U)

OVERHAUL

HINT:

S

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

S

In the RH side, work in the same procedure as in the LH side.

1.

REMOVE REAR ARMREST ASSY LH

(a)

Using a screwdriver, remove the rear armrest.

HINT:
Tape the screwdriver tip before use.

2.

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.

3.

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.

4.

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.

B58050

B59017

B59021

–

ENGINE HOOD/DOOR

REAR DOOR

75–21

1847

Author:

Date:

2004 COROLLA (RM1037U)

5.

REMOVE REAR DOOR INSIDE HANDLE SUB–ASSY
LH

(a)

Remove the inside handle and then disconnect the 2
cables from the inside handle.

6.

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.
7.

REMOVE REAR DOOR BELT MOULDING ASSY LH (See page

76–13

)

8.

REMOVE REAR DOOR GLASS RUN LH

(a)

Remove the rear door glass run.

9.

REMOVE REAR DOOR INSIDE PANEL PLATE LH

(a)

Remove the 4 screws and rear door inside panel plate.

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.

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.

B59022

B59023

B57767

75–22

–

ENGINE HOOD/DOOR

REAR DOOR

1848

Author:

Date:

2004 COROLLA (RM1037U)

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.

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.

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.

B56613

B57102

–

ENGINE HOOD/DOOR

REAR DOOR

75–23

1849

Author:

Date:

2004 COROLLA (RM1037U)

(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.

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
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)

B59023

B59497

w/o Power Window

75–24

–

ENGINE HOOD/DOOR

REAR DOOR

1850

Author:

Date:

2004 COROLLA (RM1037U)

26.

INSTALL REAR DOOR W/MOTOR LOCK ASSY LH (W/
POWER DOOR LOCK)

(a)

Install a new door lock wire harness packing.

NOTICE:

S

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

S

Be careful that no grease and dirt will stick to the
packing surface in the connecting part.

S

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

28.

INSTALL REAR DOOR WINDOW REGULATOR
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)

B59498

w/ Power Window

B59021

(A)

(A)

–

ENGINE HOOD/DOOR

REAR DOOR

75–25

1851

Author:

Date:

2004 COROLLA (RM1037U)

29.

INSTALL REAR DOOR WINDOW REGULATOR
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-
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.
Torque:
Bolt A: 6.2 N·m (63 kgf·cm, 55 in.·lbf)

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:

S

Note that the jam protection function does not operate just after resetting.

S

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:

S

When installing the service hole cover, pull out the links and connectors through the service hole cover.

S

There should be no wrinkles or folds after attaching the service hole cover.

S

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

B58054

30

"

5

_

Plate

Front

75–26

–

ENGINE HOOD/DOOR

REAR DOOR

1852

Author:

Date:

2004 COROLLA (RM1037U)

34.

INSTALL REAR DOOR WINDOW REGULATOR
HANDLE ASSY (W/O POWER WINDOW)

(a)

Install the regulator handle with the snap ring.

HINT:
With the door window fully closed, install the plate and regulator
handle with the snap ring as shown in the illustration.

750DI–02

B59012

8.0 (0.315)

mm (in.)

4.0 (0.157)

1.5 (0.059)

B50243

B59013

–

ENGINE HOOD/DOOR

LUGGAGE COMPARTMENT DOOR

75–27

1853

Author:

Date:

2004 COROLLA (RM1037U)

LUGGAGE COMPARTMENT DOOR

ADJUSTMENT

1.

INSPECT LUGGAGE COMPARTMENT DOOR PANEL SUB–ASSY

(a)

Check that the clearance is within the standard value.

2.

ADJUST LUGGAGE COMPARTMENT DOOR PANEL
SUB–ASSY

(a)

For forward/rearward and right/left adjustments, loosen
the bolts.
Torque: 7.0 N·m (71 kgf·cm, 62 in.·lbf)

(b)

For a vertical adjustment of the door front end, increase
or decrease the number of washers between the hinge
and door.
Torque: 7.0 N·m (71 kgf·cm, 62 in.·lbf)

(c)

Remove the spare wheel cover (See page

76–5

).

(d)

Remove the rear floor finish plate (See page

76–5

).

(e)

For forward/rearward and right/left adjustments, loosen
the bolts.
Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf)

(f)

Using a hammer and a brass bar, tap the striker to adjust
it.

B59018

Luggage Compartment Door Lock Assy

75–28

–

ENGINE HOOD/DOOR

LUGGAGE COMPARTMENT DOOR

1854

Author:

Date:

2004 COROLLA (RM1037U)

(g)

Perform the forward/rearward and right/left adjustments,
by loosening the bolts of the luggage compartment door.
Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf)

750DJ–02

B50229

SST

B50230

B50231

–

ENGINE HOOD/DOOR

LUGGAGE DOOR HINGE TORSION BAR RH

75–29

1855

Author:

Date:

2004 COROLLA (RM1037U)

LUGGAGE DOOR HINGE TORSION BAR RH

REPLACEMENT

HINT:

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

In the LH side, work in the same procedure as in the RH side.

Since the removal of the torsion bar will cause no tension, operation of opening and closing the door
should be carried out holding the door by hand in order to prevent the door from closing without any
resistance.

RH side torsion bar is in the upper side and LH side torsion bar is in the lower side, thus the installation
should be done in the order of RH to LH, and the removal should be done in the order of LH to RH.

1.

REMOVE LUGGAGE DOOR HINGE TORSION BAR RH

(a)

Remove the torsion bars from the center bracket.

(b)

Install SST to the torsion bar on the hinge side.
SST

09804–24010

(c)

Push down the SST, and pull the luggage compartment
door hinge from the torsion bar.

(d)

Slowly lift the SST, and remove the torsion bar from the
torsion bar bracket with SST.

(e)

Disconnect the torsion bar from the bracket.

(f)

Employ the same manner described above to the other
side.

2.

INSTALL LUGGAGE DOOR HINGE TORSION BAR RH

(a)

When installing the torsion bar, be sure to install it to the clamp securely.