FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. REPAIR INSTRUCTION

    Click here

  3. INSTALL FRONT INNER BLACK OUT TAPE

    Click here

  4. INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE

    Click here

  5. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  8. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

    Click here

  9. INSTALL FRONT DOOR LOWER FRAME GARNISH PAD


    1. B001OD2

      Install the front door lower frame garnish pad.

  10. INSTALL FRONT DOOR PANEL CUSHION


    1. B001OJO

      Engage the claw to install a new front door panel cushion.

  11. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. B001NU9

      Engage the 9 clips to install the front door No. 2 weatherstrip.

  12. INSTALL DOOR FRAME GARNISH


    1. B001OC9

      Engage the 3 claws to install the door frame garnish.

  13. INSTALL FRONT DOOR WEATHERSTRIP


    1. Clean the front door panel.

    2. B001O7UE01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 21 clips and guide, to install a new front door weatherstrip.

  14. INSTALL FRONT DOOR CHECK ASSEMBLY


    1. Apply MP grease to the sliding areas of the front door check assembly.

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B001NPCE06
      Text in Illustration
      *1 Bolt
      *2 Nut

      Install the front door check assembly with the 2 nuts and bolt.

      Torque:
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  15. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


    1. Clean the front door panel.

    2. B001OP4E05
      Text in Illustration
      *1 Double-sided Tape

      Engage the 2 guides.

    3. Install a new front door No. 2 stiffener cushion with the 2 bolts.

  16. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B001NRFE03

      Install the front door lock open rod as indicated by the arrows and in the order shown in the illustration.

  17. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.

    2. B001OCXE03
      Text in Illustration
      *a Outside
      *b Inside

      Engage the claw.

    3. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. B001NOF

      Engage the 3 clamps.

  18. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B001NXU

      Install the front door inside locking cable assembly as shown in the illustration.

    2. B001OII

      Engage the 3 claws as shown in the illustration.

  19. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B001OFS

      Install the front door lock remote control cable assembly as shown in the illustration.

  20. INSTALL FRONT DOOR LOCK ASSEMBLY

    Note


    • When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.

    • Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.

    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock assembly.


    1. Apply MP grease to the sliding parts of the front door lock assembly.

    2. When reusing the front door lock assembly:


      1. B001O8I

        Install a new door lock wiring harness seal to the front door lock assembly.

    3. B001O7RE05
      Text in Illustration
      *1 Front Door Lock Open Rod

      Insert the front door lock open rod to the front door lock assembly.

    4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.

    5. Using a T30 "TORX" socket wrench, install the front door lock assembly with the 3 screws.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  21. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B001NQJ

      Engage the 2 claws to install the front door rear outside handle pad.

  22. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B001O6K

      Engage the 3 claws to install the front door front outside handle pad.

  23. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B001NSS

      Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.

    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame sub-assembly, then slide the front door outside handle assembly toward the front of the vehicle to install it.

    3. B001NRH

      Move the lever back in the direction indicated by the arrow in the illustration to lock the front door outside handle assembly.

    4. B001OPM

      Connect the connector.

    5. Engage the 2 claws.

  24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)


    1. B001NUV

      Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.

  25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)


    1. B001OFN

      Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B001O0R

      Install the hole plug.

  26. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)


    1. B001OPY

      Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B001ODG

      Install the hole plug.

  27. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B001NOH

      Engage the guide.

    2. Install the front door rear lower frame sub-assembly with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  28. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. B001OKG

      Engage the guide.

    2. Install the front door front lower frame sub-assembly with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  29. INSTALL FRONT DOOR GLASS RUN


    1. B001NV4

      Install the front door glass run.

  30. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the power window regulator motor.


    1. B001NT2

      Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  31. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. Apply MP grease to the sliding parts of the front door window regulator assembly.

    2. Temporarily install the temporary bolt to the front door window regulator assembly.

    3. B001O2RE08
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the front door window regulator assembly with the 5 bolts.

    4. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  32. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. Connect the cable to the negative (-) battery terminal.

    2. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

    3. Disconnect the cable from the negative (-) battery terminal.

    4. Disconnect the multiplex network master switch assembly.

    5. B001NS1E04

      Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows and in the order shown in the illustration.

    6. B001NRQ

      Install the front door glass sub-assembly with the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    7. B001O52

      Install the grommet.

  33. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply new butyl tape to the front door panel.

    2. B001OK0E04
      Text in Illustration
      *a Reference Point

      Pass the front door lock remote control cable assembly and front door inside locking cable assembly through a new front door service hole cover.

    3. Attach the front door service hole cover according to the reference points on the front door panel.

      Note

      Securely install the front door service hole cover preventing wrinkles and air bubbles.

    4. B001NVZE02
      Text in Illustration
      *A for LH Side

      Engage each clamp.

    5. Connect the 2 connectors.

  34. INSTALL FRONT DOOR ARMREST SET BRACKET


    1. B001NZQ

      Install the front door armrest set bracket with the 2 screws.

  35. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  36. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B001ON5

      Engage the 2 clips to install the front door lower frame bracket garnish.

  37. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  38. INSTALL OUTER MIRROR INSTALL HOLE COVER

    Click here

  39. INSTALL OUTER MIRROR PROTECTOR

    Click here

  40. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Reverse Shift-linked Mirror)

    Click here

  41. INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel)


    1. B001OBC

      Engage the claw.

    2. Install the front door trim ornament sub-assembly with the screw.

    3. B001OC7

      Install the front door trim ornament assembly with the 11 screws.

    4. w/ Illumination:


      1. B001O80

        Engage the 3 clamps.

  42. INSTALL SEAT MEMORY SWITCH (w/ Memory)

    Click here

  43. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B001NSD

      Install the front door inner glass weatherstrip.

  44. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B001ODT

      Engage the 2 guides and claw to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

  45. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B001NOVE04
      Text in Illustration
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly

      Connect the front door lock remote control cable assembly and front door inside locking cable assembly.

    2. w/ Memory:


      1. Connect the connector.

    3. w/ Illumination:


      1. Connect the connector.

    4. B001O66E01
      Text in Illustration
      *1 Reference Boss

      Engage the front door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

    5. B001OGA

      Engage the 11 clips to temporary install the front door trim board sub-assembly.

    6. B001NNS

      Install the 3 screws to install the front door trim board sub-assembly.

  46. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. B001NU1

      Install the front door No. 1 stiffener cushion with the screw.

  47. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  48. INSTALL DOOR PULL HANDLE COVER


    1. B001O0A

      Install the door pull handle cover.

  49. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)


    1. Connect each connector.

    2. B001OAW

      Engage the 2 guides, 2 clips and 6 claws, to install the multiplex network master switch assembly with front door armrest base panel.

  50. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)


    1. Connect each connector.

    2. B001OD8

      Engage the 2 guides, 2 clips and 6 claws, to install the power window regulator switch assembly with front door armrest base panel.

  51. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B001OHK

      Engage the 3 claws to install the front door inside handle bezel plug.

  52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  53. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  54. INSPECT POWER WINDOW OPERATION

    Click here