FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RHD and LHD vehicles.

  • The procedure listed below is for the LHD vehicles.

  • Use the same procedures for both the LH and RH sides.

  • The procedure described below is for the LH side.

PROCEDURE


  1. INSTALL NO. 3 FRONT DOOR WEATHERSTRIP


    1. B002ERX

      Install the No. 3 front door weatherstrip with 4 new clips.

  2. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY


    1. B002CDF

      Install the front door panel sub-assembly with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      CAUTION:

      Be sure to perform this procedure with 2 or more persons as the part is very heavy.

    2. B002CAM

      Connect the front door wire to the front door panel sub-assembly with the 2 bolts.

    3. B002CJ5

      Engage the clamps of the front door wire.

  3. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  4. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

    Click here

  5. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  6. INSTALL FRONT DOOR REAR BELT MOULDING END COVER

    Click here

  7. INSTALL FRONT DOOR WEATHERSTRIP


    1. B002CXB

      Engage the clips to install the front door weatherstrip.

  8. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole on the vehicle body.

    3. Clean the threads of the bolt.

    4. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    5. B002E8D

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

      Torque
      Nut
      8.0 N*m (82 kgf*cm, 71 in.*lbf)
      Bolt
      27 N*m (275 kgf*cm, 20 ft.*lbf)

  9. INSTALL FRONT DOOR DUST PROOF SEAL

    Tech Tips

    Use the same procedure for all front door dust proof seals.


    1. B002DIT

      Engage the claw to install a new front door dust proof seal.

  10. INSTALL FRONT DOOR PANEL CUSHION


    1. B002CZI

      Install a new front door panel cushion.

  11. INSTALL NO. 2 FRONT DOOR WEATHERSTRIP


    1. B002CJ3

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

  12. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B002CMMC02
      *a Snap

      Install the front door lock open rod to the front door outside handle frame sub-assembly.

    2. Rotate the snap as shown in the illustration to engage the snap to the front door lock open rod.

  13. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. B002D7G

      Engage the clamps to connect the wire harness.

    3. B002EJ3C01
      B002C8N Install in this Direction

      Install the front door outside handle frame sub-assembly as shown in the illustration.

    4. Using a T30 "TORX" socket wrench, tighten the screw.

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

  14. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

    B002DY3C01
    B002C8N Install in this Direction

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

  15. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B002DDLC01
      B002C8N Install in this Direction

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

  16. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. Apply MP grease to the sliding area of the front door outside handle assembly.

    2. B002CC8C01
      B002C8N Install in this Direction

      Install the front door outside handle assembly as shown in the illustration.

    3. B002EP8C01
      *a Holder
      B002C8N Install in this Direction

      Engage the holder as shown in the illustration.

    4. B002E85

      Connect the connector.

    5. B002DAXC01
      B002C8N Install in this Direction

      Engage the claws of the connector cover to connect the connector cover.

  17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

    Click here

  18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

    Click here

  19. INSTALL FRONT DOOR LOCK ASSEMBLY

    Click here

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


    1. B002D0DC01
      *1 Hole Plug
      B002C8N Install in this Direction

      Install the front door outside handle cover RH as shown in the illustration.

    2. Using a T30 "TORX" socket wrench, install the screw.

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

    3. Install the hole plug.

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


    1. B002DD7

      Engage the claws to install the front door outside handle cover LH.

  22. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)


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

    2. B002EN4C01
      *1 Hole Plug
      B002C8N Install in this Direction

      Install the front door lock cylinder assembly as shown in the illustration.

      Tech Tips

      Check that the front door lock cylinder assembly are attached to the door correctly.

    3. Using a T30 "TORX" socket wrench, install the screw.

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

    4. Install the hole plug.

  23. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION


    1. Clean vehicle installation surface.

    2. B002CFNC02
      *a Double-side Tape

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

      Tech Tips

      Peel off the backing paper from the double-sided tape before installing the No. 2 front door stiffener cushion.

    3. Press the double-side tape area of the No. 2 front door stiffener cushion.

  24. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B002CKS

      Engage the guide to install the front door rear lower frame sub-assembly.

    2. Install the 2 bolts.

  25. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  26. INSTALL OUTER MIRROR PROTECTOR

    Click here

  27. INSTALL FRONT MULTIPLEX NETWORK DOOR ECU

    Click here

  28. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY


    1. Apply MP grease to the sliding areas of the front door window regulator sub-assembly.

    2. B002E3HC02
      *a Temporary Bolt

      Temporarily install the temporary bolt to the front door regulator sub-assembly.

    3. Temporarily install the front door window regulator sub-assembly.

    4. Install the front door window regulator sub-assembly with the 6 bolts.

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

    5. Connect the connector.

  29. INSTALL FRONT DOOR BELT MOULDING

    Click here

  30. INSTALL FRONT DOOR GLASS RUN


    1. B002ETO

      Install the front door glass run.

  31. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. Connect the power window regulator master switch assembly.

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

    3. Move the front door glass sub-assembly so that the door glass bolt holes can be seen.

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

    5. Disconnect the power window regulator master switch assembly.

    6. B002CTQC01
      B002C8N Install in this Direction (1)
      B002E01 Install in this Direction (2)

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

    7. B002ERA

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  33. INSTALL FRONT DOOR NO. 2 SERVICE HOLE COVER

    Click here

  34. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. B002DVUC01
      *1 Butyl Tape
      *a Reference Point

      Apply new butyl tape to the front door panel sub-assembly.

    2. 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. Install the front door service hole cover according to the reference points on the front door panel sub-assembly.

      Note

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

  35. INSTALL FRONT DOOR ARMREST SET BRACKET


    1. B002DBN

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

  36. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP

    B002CVTC01
    B002C8N Install in this Direction

    1. Install the front door glass inner weatherstrip as shown in the illustration.

  37. INSTALL DOOR FRAME GARNISH


    1. B002F1F

      Engage the clips to install the door frame garnish.

  38. INSTALL FRONT DOOR TRIM COVER


    1. B002CHN

      Engage the clips to install the front door trim cover.

  39. INSTALL NO. 1 FRONT DOOR STIFFENER CUSHION


    1. B002EFU

      Install a new No. 1 front door stiffener cushion.

  40. INSTALL FRONT DOOR TRIM SEAL


    1. B002E75

      Engage the clips to install the front door trim seal.

  41. INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY


    1. B002C6D

      Engage the claws to install the front door trim ornament sub-assembly from the No. 1 interior illumination light assembly.

  42. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B002DNT

      Engage the claw to install the front door inside handle sub-assembly.

    2. Install the screw.

    3. B002DQE

      Install the front door inside handle sub-assembly together with the front door trim ornament sub-assembly and No. 1 interior illumination light assembly with the 15 screws.

  43. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY

    Click here

  44. INSTALL SEAT MEMORY SWITCH

    Click here

  45. INSTALL FRONT SEAT SLIDE SWITCH BEZEL

    Click here

  46. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B002DO1C01
      *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. Connect each connector.

    3. B002CIUC01
      *a Reference Boss

      Engage the claws to install the front door trim board sub-assembly to the front door glass inner weatherstrip.

    4. Engage the reference boss in the direction indicated by the arrow in the illustration.

    5. B002CQH

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

    6. Install the 3 screws.

  47. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  48. INSTALL FRONT ARMREST BASE UPPER PANEL


    1. Connect the connector.

    2. B002ELT

      Engage the claws and clips to install the front armrest base upper panel.

  49. INSTALL FRONT DOOR HOLE COVER


    1. B002DJF

      Install the front door hole cover.

  50. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B002CU9C01
      B002C8N Install in this Direction

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

  51. ADJUST FRONT DOOR PANEL SUB-ASSEMBLY

    Click here

  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. CHECK POWER WINDOW CONTROL SYSTEM

    Click here