Toyota 4Runner 2001-06

Locks & Lock Systems

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Power Door Locks



Diagnosis & Testing
2001-02 Models
  1. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 2, and check that the door lock link moves to UNLOCK position.
  2.  
  3. Reverse the polarity and check that the door lock link moves to LOCK position.
  4.  
  5. If the operation is not as specified, replace the door lock assembly.

    Click image to see an enlarged view

    Fig. Connect the door lock motor to the battery as shown to move the lock to the UNLOCK position. Reverse it to move it to LOCK position-2001-02 Models

  6.  
  7. Connect the leads of an ohmmeter the driver-s door lock control switch. There should be continuity between terminals 4 and 6 with the switch in the LOCK position. There should be continuity between terminals 4 and 12 with the switch in the UNLOCK position. If there is not, the switch should be replaced.

    Click image to see an enlarged view

    Fig. Driver-s door lock control switch terminals-2001-02 Models

  8.  
  9. Connect the leads of an ohmmeter the passenger-s door lock control switch. There should be continuity between terminals 3 and 6 with the switch in the LOCK position. There should be continuity between terminals 3 and 5 with the switch in the UNLOCK position. If there is not, the switch should be replaced.

    Click image to see an enlarged view

    Fig. Passenger-s door lock control switch terminals-2001-02 Models

  10.  

2003-05 Models
  1. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 4, and check that the door lock link moves to UNLOCK position.
  2.  
  3. Reverse the polarity and check that the door lock link moves to LOCK position.
  4.  
  5. If the operation is not as specified, replace the door lock assembly.

    Click image to see an enlarged view

    Fig. Door lock motor terminals for testing-2003-05 Models

  6.  
  7. Connect the leads of an ohmmeter the driver-s door lock control switch. There should be continuity between terminals 1 and 5 with the switch in the LOCK position. There should be continuity between terminals 1 and 8 with the switch in the UNLOCK position. If there is not, the switch should be replaced.

    Click image to see an enlarged view

    Fig. Driver-s door lock control switch terminals-2003-05 Models

  8.  
  9. Connect the leads of an ohmmeter the passenger-s door lock control switch. There should be continuity between terminals 3 and 6 with the switch in the LOCK position. There should be continuity between terminals 3 and 5 with the switch in the UNLOCK position. If there is not, the switch should be replaced.

    Click image to see an enlarged view

    Fig. Passenger-s door lock control switch terminals-2003-05 Models

  10.  

Removal & Installation
Door Lock Motor
2001-02 Models
Back Door (Rear Hatch)


Click image to see an enlarged view

Fig. Exploded view of the back door (rear hatch) components-2001-02 Models

  1. Remove the assist strap hole cover, bolt and assist strap.
  2.  
  3. Using a screwdriver, remove the back door trim cover.
    NOTE
    Tape the screwdriver tip before use to avoid damaging the trim pieces.

  4.  
  5. Remove the plate and disconnect the electrical connector.
  6.  
  7. Remove the back door glass.
  8.  
  9. Remove the window regulator and glass guide rail.
  10.  
  11. Remove the lock control bellcrank.
  12.  
  13. Remove the back door remote control.
  14.  
  15. Remove the back door trim garnish around the license plate.
  16.  
  17. Remove the mounting bolts and remove the door lock.
  18.  

To install:

  1. Installation is the reverse order of removal. Tighten the door lock mounting bolts to 61 inch lbs. (7 Nm).
  2.  

Front Door


Click image to see an enlarged view

Fig. Exploded view of the front door components-2001-02 Models

  1. Using a screwdriver, remove the power window switch by pulling upward, then disconnect the connector.
    NOTE
    Tape the screwdriver tip before use to avoid damaging the trim pieces.

  2.  
  3. Remove the two clips and two screws, then insert a screwdriver between the retainer and door trim to pry it loose. Pull the door trim upward to remove it.
  4.  
  5. Using a screwdriver, remove the rear mirror inner cover. If equipped with the electrical retraction system, disconnect the connector and remove the clip. Remove the three bolts and rear view mirror.
  6.  
  7. Remove the two grommets and remove the service hole cover.
  8.  
  9. Pry loose the clips from the edge of the panel, and remove the inner and outer weatherstrip.
  10.  
  11. Remove the bolt and nut and pull out the front lower frame.
  12.  
  13. Remove the two bolts and pull out the rear lower frame.
  14.  
  15. Remove the door glass run, locking knob and protector.
  16.  
  17. Disconnect the link from the outside handle. Disconnect the door lock electrical connector.
  18.  
  19. Remove the three Torx® screws and bolt from the door lock.
  20.  
  21. Remove the two bolts from the outside handle.
  22.  
  23. Remove the door lock with outside handle through the service hole.
  24.  
  25. Disconnect the link from the outside handle and remove the outside handle from the door lock.
  26.  
  27. Installation is the reverse order of removal. All bolts should be tightened to 43 inch lbs. (5 Nm).
  28.  

2003-05 Models


Click image to see an enlarged view

Fig. Exploded view of the front door components-2003-05 Models



Click image to see an enlarged view

Fig. Exploded view of the rear door (rear hatch) components-2003-05 Models

Back Door (Rear Hatch)
  1. Remove the assist strap hole cover, bolt and assist strap.
  2.  
  3. Using a screwdriver, remove the back door trim cover.
    NOTE
    Tape the screwdriver tip before use to avoid damaging the trim pieces.

  4.  
  5. Using a trim clip remover, remove the 10 clips and trim board.
  6.  
  7. Remove the inner weatherstrip.
  8.  
  9. Remove the back door left side service hole cover.
  10.  
  11. Disconnect the back door lock electrical connector.
  12.  
  13. Remove the two back window regulator control wires.
  14.  
  15. Disengage the two claws and remove the lock protector as shown in the illustration.
  16.  
  17. Remove the four mounting bolts and back door lock.

    Click image to see an enlarged view

    Fig. Removing the back door (rear hatch) lock assembly-2003-05 Models

  18.  

To install:

Click image to see an enlarged view

Fig. Install the regulator control wires as shown-2003-05 Models



Click image to see an enlarged view

Fig. Apply butyl tape to the door and install the service hold cover-2003-05 models

  1. Install the door lock and tighten the mounting bolts to 71 inch lbs. (8 Nm). Connect the electrical connector. Install the door lock protector.
  2.  
  3. Install the two regulator control wires as shown in the illustration.
  4.  
  5. Apply butyl tape to the door and install the service hole cover, as shown in the illustration.
    NOTE
    There should be no wrinkles or folds after attaching the service hole cover.


    NOTE
    After attaching the service hole cover, check the sealing condition.

  6.  
  7. The remainder of the installation is the reverse order of removal.
  8.  

Front Door
  1. Using a screwdriver, remove the lower frame bracket garnish.
    NOTE
    Tape the screwdriver tip before use to avoid damaging the trim pieces.

  2.  
  3. Using a screwdriver, disengage the 3 claws, and remove the inside handle bezel.
  4.  
  5. Disengage the claws, and remove the armrest from the trim board.
  6.  
  7. To remove the door panel, remove the 2 cushion rubbers, 2 screws and clips. Use a trim clip remover, and remove the 11 clips. Remove the door panel upward.
    NOTE
    In order to prevent the door from being damaged, cover the parts indicated by arrow marks in the illustration with tape.



    Click image to see an enlarged view

    Fig. Remove the clips to remove the door panel. Tape the door indicated by arrows to prevent damage-2003-05 Models

  8.  
  9. Disconnect the 2 cables from the inside handle as shown
  10.  
  11. Remove the inner weatherstrip.
  12.  
  13. Remove the 3 screws and power window master switch.
  14.  
  15. Disengage the 4 claws and remove the power mirror switch.
  16.  
  17. Remove the door service hole cover and remove the remaining tape on the door side.
  18.  
  19. Disconnect the outer rear view mirror connector and remove the three nuts and outer rear view mirror.
    NOTE
    When the nuts are removed, the outer rear view mirror might fall.

  20.  
  21. Remove the electrical connectors, bolts and speakers.
  22.  
  23. Remove the rear window frame molding.
  24.  
  25. Remove the door glass outer weatherstripping.
    NOTE
    Insert a shop rag inside the door panel to prevent the glass from being scratched.

  26.  
  27. Open the door glass until the bolts appear in the service holes.
  28.  
  29. Remove the 2 bolts and holding the door glass.
  30.  
  31. Remove the door glass, lifting the rear side first and then upward.
  32.  
  33. Remove the door window regulator through the service hole.
  34.  
  35. Remove the power window motor.
  36.  
  37. Remove the bolt and lower rear door sub-frame.
  38.  
  39. Remove the hole plug and using a Torx® socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.
  40.  
  41. Disconnect the door lock connector. Using a Torx® socket wrench (T30), remove the 3 screws and door lock through the service hole. Remove the door lock wire harness packing.
  42.  

To install:

  1. Apply multipurpose grease to the sliding and rotating parts of the door lock. Install a new door lock wire harness packing. Insert the outside handle link into the lock with the door motor, and then set it to the door panel.
  2.  
  3. Using Loctite® on the three screws, install the door lock and connect the electrical connector.
  4.  
  5. Using a Torx® wrench (T30), install the outside handle cover and tighten the screw to 35 inch lbs. (7 Nm). Install the hole plug.
  6.  
  7. Install the lower rear door sub-frame and tighten the bolt to 42 inch lbs. (5 Nm).
  8.  
  9. Install the power window motor and regulator assembly.
  10.  
  11. Install the door glass.
  12.  
  13. Install the speakers.
  14.  
  15. Install the outer rear view mirror and tighten the nuts to 71 inch lbs. (8 Nm). Connect the electrical connector.
  16.  
  17. Apply butyl tape to the door as shown and install the service hole cover. 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, check the sealing condition.
  18.  
  19. The remainder of the installation is the reverse order of removal.
  20.  

Door Lock Switch

The door locks are removed while removing the door panels. For additional information, see the following topic: -Door Lock Motor, Removal & Installation-.

 
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