FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The following procedure is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

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

    Click here

  2. INSTALL FRONT DOOR BELT MOULDING

    Click here

  3. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

    Click here

  4. INSTALL FRONT DOOR PANEL CUSHION


    1. B004E6A

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

  5. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. B004FXX

      Engage the 8 clips to install the front door No. 2 weatherstrip.

  6. INSTALL FRONT DOOR WEATHERSTRIP


    1. B004EVO

      Engage the 20 clips to install the front door weatherstrip.

  7. 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. B004G99C02
      B004FMB Nut
      B004EIV Bolt

      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 }

  8. INSTALL FRONT DOOR VENT SEAL


    1. B004ES8

      Install the front door vent seal.

  9. INSTALL FRONT DOOR DIVISION BAR SEAL


    1. B004F9K

      Engage the claw.

    2. Engage the 2 clips to install the front door division bar seal.

  10. INSTALL DOOR GLASS FEMALE STABILIZER


    1. B004EYQ

      Engage the 2 guides.

    2. Install the door glass female stabilizer with the bolt.

      Torque:
      11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }

  11. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B004EV8N01

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

  12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. B004FHCC01
      *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. B004GQI

      Engage the 3 clamps.

  13. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

    Note


    • When reusing a removed front door lock with motor assembly, replace the door lock wire harness seal with a new one.

    • Do not allow grease or dust to adhere to the door lock wire harness seal installation surface.

    • Reusing a door lock wire harness seal or using a damaged door lock wire harness seal may cause water ingress. This may result in a malfunction of the front door lock with motor assembly.


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

    2. When reusing the front door lock with motor assembly:


      1. B004E5Y

        Install a new door lock wire harness seal to the front door lock with motor assembly.

    3. B004ELIC01
      *1 Front Door Lock Open Rod

      Connect the front door lock open rod to the front door lock with motor assembly.

      Tech Tips

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

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

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

    5. Connect the connector.

  14. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B004FM8

      Engage the 3 guides as shown in the illustration.

    2. B004F85

      Engage the claw to install the front door rear outside handle pad.

  15. INSTALL FRONT DOOR OUTSIDE HANDLE PAD


    1. B004F7W

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

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


    1. B004FXS

      Engage the 2 guides and claw.

    2. 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 }
    3. B004E4W

      Install the hole plug.

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


    1. B004G0X

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B004G8K

      Install the hole plug.

  18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B004EJB

      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. B004FRT

      Move the lever as shown in the illustration and engage the 2 claws to lock the front door outside handle assembly.

    4. Connect the connector.

    5. B004GP6

      Engage the 2 claws.

  19. INSTALL FRONT DOOR GLASS RUN


    1. B004EZM

      Engage the guide to install the front door glass run.

  20. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. B004EFZN01

      Using a 4 mm hexagon wrench, adjust the 2 stud bolts at the bottom of the front door window regulator assembly as shown in the illustration.

      Standard Clearance
      A 21.1 to 22.1 mm (0.831 to 0.870 in.)

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

    3. B004GJE

      Temporarily install the front door window regulator assembly with the 7 nuts.

    4. B004ESH

      Install the 2 window regulator shims.

    5. B004GJEN01

      Tighten the 7 nuts to install the front door window regulator assembly.

      Torque:
      Nut (A)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      Nut (B)
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    6. B004FH2

      Connect the connector.

  21. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. for Driver Side:


      1. Connect the multiplex network master switch assembly and move the front door window regulator assembly so that the door glass stud bolts can be seen.

    3. for Front Passenger Side:


      1. Connect the power window regulator switch assembly and move the front door window regulator assembly so that the door glass stud bolts can be seen.

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

    5. for Driver Side:


      1. Disconnect the multiplex network master switch assembly.

    6. for Front Passenger Side:


      1. Disconnect the power window regulator switch assembly.

    7. B004FOPN01

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

    8. B004EKI

      Install the front door glass sub-assembly with the 3 nuts.

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

  22. INSTALL FRONT DOOR UPPER WINDOW STOP


    1. for Front Side:


      1. B004ECD

        Install the front door upper window stop with the bolt.

        Torque:
        11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }

    2. for Rear Side:


      1. B004GGL

        Install the front door upper window stop with the bolt.

        Torque:
        11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }

  23. INSPECT FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. for Driver Side:


      1. Connect the multiplex network master switch assembly and fully close the front door glass sub-assembly.

    3. for Front Passenger Side:


      1. Connect the power window regulator switch assembly and fully close the front door glass sub-assembly.

    4. Check that the clearance measurements of areas a through m are within each standard range.

      B004G5EN01
      Standard Clearance
      Area Measurement Area Measurement
      a 15.0 mm (0.591 in.) b 5.6 to 9.6 mm (0.220 to 0.378 in.)
      c 9.1 to 13.1 mm (0.358 to 0.516 in.) d 15.0 mm (0.591 in.)
      e 5.7 to 9.7 mm (0.224 to 0.382 in.) f 9.1 to 13.1 mm (0.358 to 0.516 in.)
      g 15.0 mm (0.591 in.) h 5.7 to 9.7 mm (0.224 to 0.382 in.)
      i 9.1 to 13.1 mm (0.358 to 0.516 in.) j 12.0 mm (0.472 in.)
      k 0 mm (0 in.) l 12.0 mm (0.472 in.)
      m 0 mm (0 in.) - -

      Note

      Be careful not to cut the weatherstrip during door glass adjustment.

  24. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY


    1. B004G5H

      Adjust the fit of the top part of the front door glass sub-assembly inward and outward.


      1. Loosen the 2 nuts at the bottom of the front door window regulator assembly.

      2. Using a 4 mm hexagon wrench, turn the 2 stud bolts to adjust the fit of the top part of the front door glass sub-assembly inward and outward.

        Tech Tips

        When the stud bolt are turned counterclockwise, the top part of the front door glass sub-assembly moves toward the inside of the vehicle. When the stud bolt are turned clockwise, the top part of the front door glass sub-assembly moves toward the outside of the vehicle.

      3. Tighten the 2 nuts after adjustment.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. B004EWT

      Adjust the fit of the bottom part of the front door glass sub-assembly inward and outward.


      1. Loosen the 2 nuts at the top of the front door window regulator assembly.

      2. Change the number of installed window regulator shims to adjust the fit of the bottom part of the front door glass sub-assembly inward and outward.

        Tech Tips

        When more shims are used, the bottom part of the front door glass sub-assembly moves toward the outside of the vehicle. When less shims are used, the bottom part of the front door glass sub-assembly moves toward the inside of the vehicle.

      3. Tighten the 2 nuts after adjustment.

        Torque:
        5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    3. B004ECZ

      Adjust the front door glass sub-assembly fully closed position horizontally and vertically.


      1. Loosen the 2 front door upper window stop bolts and temporarily move the front door upper window stops to the top of their adjustment range and then temporarily tighten the bolts.

      2. Loosen the 3 front door glass sub-assembly nuts.

      3. Stop the front door glass sub-assembly approximately 3 mm (0.118 in.) below the fully closed position.

      4. While holding the front door glass sub-assembly, move it vertically and horizontally to adjust its position.

      5. Tighten the 3 nuts after adjustment.

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

      6. Move the front door glass sub-assembly to the fully closed position.

      7. Loosen the 2 front door upper window stop bolts.

      8. While lightly pushing each front door upper window stop against the stopper on the front door glass sub-assembly, tighten each bolt.

        Torque:
        11.5 N*m  { 117 kgf*cm, 102 in.*lbf }

    4. for Driver Side:


      1. Disconnect the multiplex network master switch assembly.

    5. for Front Passenger Side:


      1. Disconnect the power window regulator switch assembly.

    6. Disconnect the cable from the negative (-) auxiliary battery terminal.

  25. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    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. B004FBCC01
      *a Reference Point

      Install 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.

  26. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  27. INSTALL FRONT DOOR TRIM BRACKET


    1. B004ETV

      Install the front door trim bracket with the 2 screws.

  28. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B004FXF

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

  29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  30. INSTALL OUTER MIRROR PROTECTOR

    Click here

  31. INSTALL OUTER MIRROR INSTALL HOLE COVER

    Click here

  32. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)

    Click here

  33. INSTALL DOOR SIDE AIRBAG SENSOR

    Click here

  34. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B004E4H

      Engage the 9 claws to install the front door inner glass weatherstrip as shown in the illustration.

  35. INSTALL SEAT MEMORY SWITCH (w/ Memory)

    Click here

  36. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B004GBN

      Install the front door inside handle sub-assembly with the 7 screws.

  37. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY

    Click here

  38. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B004F54C01
      *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. B004FVD

      Engage the 9 clips to install the front door trim board sub-assembly as shown in the illustration.

    4. B004F2ZN01

      Install the 4 screws.

      Torque:
      Screw (A)
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  39. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. B004E7C

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

  40. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  41. INSTALL DOOR TRIM COVER


    1. B004F7S

      Install the door trim cover.

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


    1. Connect the connector.

    2. B004G5UC01
      B004FO9 Push Area

      Engage the 2 clips, 7 claws and 5 guides to install the multiplex network master switch assembly with front door armrest base panel.

    3. Press the push area.

      Tech Tips

      Check that the front door armrest base panel are attached to the front door trim board sub-assembly correctly.

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


    1. Connect the connector.

    2. B004E24C01
      B004FO9 Push Area

      Engage the 2 clips, 7 claws and 5 guides to install the power window regulator switch assembly with front door armrest base panel.

    3. Press the push area.

      Tech Tips

      Check that the front door armrest base panel are attached to the front door trim board sub-assembly correctly.

  44. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B004E10

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

  45. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

    Click here

  46. INSTALL BATTERY SERVICE HOLE COVER LH

    Click here

  47. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  48. INSPECT POWER WINDOW OPERATION

    Click here

  49. INSPECT SRS WARNING LIGHT

    Click here