FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the LHD vehicles.

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

  • The following procedure is for the LH side.

  • A bolt without a torque specification is shown in the standard bolt chart.

    Click here

PROCEDURE


  1. INSTALL STEP PANEL WIRE LH


    1. Attach the clamp to install the step panel wire LH.

  2. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH


    1. Remove the peeling paper from the face of a new front door No. 2 weatherstrip LH.

      Tech Tips

      After removing the peeling paper, keep the exposed adhesive free from foreign matter.

    2. B0049THC01
      *1 Grommet
      B004CG0 Double-sided Tape

      Attach the grommet and double-sided tape.

    3. Attach the clips to install the front door No. 2 weatherstrip LH.

      Tech Tips

      Press the front door No. 2 weatherstrip LH firmly to install it.

  3. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

    Click here

  4. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY LH


    1. Put the outside door handle in the full stroke position and install the front door lock cylinder assembly LH.

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

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

  5. INSTALL OUTSIDE DOOR HANDLE SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding area of the outside door handle sub-assembly LH.

    2. Temporarily install the outside door handle sub-assembly LH with the 4 bolts.

    3. B0049ZHC02
      B004C4F Bolt
      B004ANI Connector

      Tighten the 4 bolts in the order shown in the illustration to install the outside door handle sub-assembly LH.

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

      Note

      When tightening the handle, check there is no significant gaps or differences.

    4. Connect the 4 connectors and attach the clamp.

    5. Remove the protective tape.

  6. INSTALL FRONT DOOR PANEL CUSHION


    1. B004ABR

      Attach the claws to install a new front door panel cushion.

  7. INSTALL HOLE PLUG


    1. B004BB5

      for Front Door Inside Panel Side:

      Install the 2 hole plugs.

    2. B004CT3

      for Front Door Outer Panel Side:

      Install the hole plug.

  8. INSTALL FRONT DOOR WIRE LH


    1. B004BK3

      Attach the clamps to install the front door wire LH.

  9. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. B004B00N01

      Using a 4.0 mm hexagon wrench, adjust the 2 stud bolts at the bottom of the front door window regulator assembly LH as shown in the illustration.

      Standard Clearance
      Area Specified Condition
      A 20.9 to 21.9 mm (0.823 to 0.862 in.)

    2. Apply MP grease to the sliding and rotating areas of the front door window regulator sub-assembly LH.

    3. B004B8TC03
      B004C4F Nut
      B004ANI Connector

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

    4. Connect the connector.

    5. B004AZCC01
      B004C4F Nut <A>
      B004ANI Nut <B>

      Tighten the 2 nuts <A> and 3 nuts <B>.

      Torque:
      Nut <A>
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      Nut <B>
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  10. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run LH for the front door front lower frame sub-assembly LH.

      Note

      Make sure the hole on the end of the front door glass run LH is fitted securely to the protrusion on the lower part of the front door front lower frame sub-assembly LH.

  11. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH


    1. Install the front door front lower frame sub-assembly LH with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  12. INSTALL FRONT DOOR UPPER WINDOW STOP


    1. B004CO8

      Temporarily install the 2 front door upper window stops.

  13. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. B004AKCC01
      B004B1M Install in this Direction (1)
      B004CNL Install in this Direction (2)

      Slide the front door glass sub-assembly LH in the direction of the arrows shown in the illustration and install it to the carrier plate of the front door window regulator sub-assembly LH.

    2. B004CH2

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. B004AV9

      Tighten the 2 bolts to install the 2 front door upper window stops.

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

      Note

      Be careful not to damage the front door glass sub-assembly LH.

    4. B004B95C02
      B004B1M Move in this Direction
      B004C4F Bolt

      Lift up the front door glass sub-assembly LH and install the door window female stabilizer LH with the bolt.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    5. B004A9O

      Install the 2 window regulator shims.

    6. B004CQN

      Tighten the 2 nuts to install the front door window regulator sub-assembly LH.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    7. B004APO

      Install the 5 hole plugs.

  14. INSTALL FRONT DOOR CHECK ASSEMBLY LH


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

    2. Install the front door check assembly LH with the 2 nuts.

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

  15. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY LH

    Click here

  16. INSTALL FRONT DOOR INSIDE PANEL SUB-ASSEMBLY LH

    Note


    • Although CFRP material has high strength, there is a possibility of cracking if an excessive load is applied. As a result, pay attention to how it is handled.

    • Perform this operation with 2 or more people because of the risk of deformation or damage.

    • Be careful not to damage the front door glass sub-assembly LH.

    • There are limited gaps between the end of the bolts and the door outer panel and readjusting the threading by tapping is difficult. As a result, the front door inside panel sub-assembly LH installation bolts and "TORX" screw ((7) and (8) in the illustration) should only be temporarily installed as not to damage the threads.


    1. B004CPNC01
      B004B1M Install in this Direction

      Attach the center door guide piece on the front door panel sub-assembly LH of the arrow shown in the illustration.

    2. Temporarily install the "TORX" bolt, 7 "TORX" screws and 3 front door inside plates.

    3. Temporarily install the 4 bolts.

    4. B004C9YC02
      B004C4F "TORX" screw
      B004ANI Bolt
      B004BQJ

      "TORX" bolt

      (w/ Rubber Cushion)
      B004C8Q

      Front Door Inside Panel Plate

      ("TORX" screw)

      Tighten the bolt, "TORX" bolt, "TORX" screw and front door inside plate in the order shown in the illustration.


      1. "TORX" screw:

        Using a T30 "TORX" socket wrench, tighten the 7 "TORX" screws.

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

      2. Bolt:

        Tighten the 4 bolts.

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

      3. "TORX" bolts (w/ Rubber Cushion)

        Using a T30 "TORX" socket wrench, tighten the "TORX" bolts.

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

      4. Front door inside panel plate:

        Using a T30 "TORX" socket wrench, tighten the 3 front door inside panel plates.

        Torque:
        11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    5. B004BEO

      Attach the clamps.

    6. B004A41C01
      B004B1M Close in this Direction

      Connect the connector.

    7. Close the wiring protector and attach the claw.

    8. B004B7OC01
      B004C4F Grommet
      B004ANI Connector

      Connect the 2 connectors and install the grommet.

    9. B004CG4

      Connect the front door wire harness connector and attach the claws.

    10. Clean the bolt hole on the vehicle body.

    11. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    12. B004CS2

      Install the bolt.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    13. B004A4ZC01
      B004B1M Install in this Direction

      Insert your hand into the service hole, attach the door lock side rod and install the snap lock.

  17. INSPECT FRONT DOOR GLASS SUB-ASSEMBLY LH


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

      B0049Z7N02
      Standard Clearance
      Area Measurement Area Measurement

      A

      (Reference)

      		 15.0 mm (0.591 in.) B 3.1 to 7.1 mm (0.122 to 0.280 in.)
      C 8.7 to 12.7 mm (0.343 to 0.500 in.)

      D

      (Reference)

      		 15.0 mm (0.591 in.)
      E 3.2 to 7.2 mm (0.126 to 0.283 in.) F 8.5 to 12.5 mm (0.335 to 0.492 in.)

      G

      (Reference)

      		 15.0 mm (0.591 in.) H 3.2 to 7.2 mm (0.126 to 0.283 in.)
      I 7.6 to 11.6 mm (0.299 to 0.457 in.) J 10.0 to 14.0 mm (0.394 to 0.551 in.)

      K

      (Reference)

      		 0 mm (0 in.) L 10.0 to 14.0 mm (0.394 to 0.551 in.)

      M

      (Reference)

      		 0 mm (0 in.) - -

  18. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. B004BPQ

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


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

      2. Using a 4.0 mm hexagon wrench, turn the 2 stud bolts to adjust the fit of the top part of the front door glass sub-assembly LH inward and outward.

        Tech Tips

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

        When the stud bolt are turned counterclockwise, the top part of the front door glass sub-assembly LH moves toward the inside of the vehicle. When the stud bolt are turned clockwise, the top part of the front door glass sub-assembly LH 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. B004A9O

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


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

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

        Tech Tips


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


        • The thickness of one window regulator shim is 1.0 mm (0.039 in.).

      3. Tighten the 2 nuts after adjustment.

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

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

      Click here

    4. for Driver Side:

      Connect the No. 2 front door wire LH, multiplex network master switch assembly and front door multiplex network ECU LH connectors.

    5. for Front Passenger Side:

      Connect the No. 2 front door wire RH, power window regulator switch assembly and front door multiplex network ECU RH connectors.

    6. B004C43C01
      B004C4F Front Door Upper Window Stop
      B004ANI Nut

      Adjust the front door glass sub-assembly LH 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 install the bolts.

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

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

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

      5. Tighten the 3 nuts after adjustment.

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

      6. Move the front door glass sub-assembly LH 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, 8 ft.*lbf }

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

      Click here

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

      B004A52

      Note

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

      Click here

    8. for Driver Side:

      Disconnect the No. 2 front door wire LH, multiplex network master switch assembly and multiplex network front door ECU LH connector.

    9. for Front Passenger Side:

      Disconnect the No. 2 front door wire RH, power window regulator switch assembly and multiplex network front door ECU RH connector.

  19. INSTALL REAR ACCESS PANEL WEATHERSTRIP LH


    1. Remove the peeling paper from the face of a new rear access panel weatherstrip LH.

    2. B004AHHC01
      *a Clip <A>
      B004CG0 Double-sided Tape

      Attach the double-sided tape.

    3. Install the clip <A>.

    4. Attach the clips to install the rear access panel weatherstrip LH.

      Tech Tips

      Press the rear access panel weatherstrip LH firmly to install it.

  20. INSTALL FRONT DOOR TRIM SEAL LH


    1. B004ANO

      Attach the clips to install the front door trim seal LH.

  21. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. Remove the peeling paper from the face of a new front door weatherstrip LH.

    2. B004C6KC02
      B004CG0 Double-sided Tape

      Attach the double-sided tape.

    3. Attach the clips to install the front door weatherstrip LH.

      Tech Tips

      Press the front door weatherstrip LH firmly to install it.

  22. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP LH


    1. B004A6Q

      Install the front door No. 3 weatherstrip LH with the 3 clips.

  23. INSTALL FRONT DOOR DIVISION BAR SEAL LH


    1. B004BPI

      Install the front door division bar seal LH with the 2 clips.

  24. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER LH

    Click here

  25. INSTALL DOOR SIDE AIRBAG SENSOR LH

    Click here

  26. INSTALL NO. 1 FRONT DOOR HOLE COVER SUB-ASSEMBLY LH

    Click here

  27. INSTALL FRONT DOOR MULTIPLEX NETWORK ECU LH


    1. B004C39C03
      B004C4F Screw
      B004ANI Connector

      Install the front door multiplex network ECU LH with the 2 screws.

    2. Connect the 3 connectors.

  28. INSTALL NO. 1 SPEAKER ASSEMBLY WITH BOX

    Click here

  29. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. B004AFE

      Attach the clips to install the front door lower frame bracket garnish LH.

  30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  31. INSTALL NO. 2 FRONT DOOR WIRE LH


    1. Connect the connector, attach all of the each clamps to install the No. 2 front door wire LH.

  32. INSTALL SEAT MEMORY SWITCH (for Driver Side)

    Click here

  33. INSTALL INDICATOR LIGHT COVER

    Click here

  34. INSTALL INDICATOR LIGHT BRACKET

    Click here

  35. INSTALL INDICATOR LIGHT ASSEMBLY

    Click here

  36. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. B004AF9

      Bend the claws as shown in the illustration and install the front door inner glass weatherstrip LH to the front door trim board sub-assembly LH.

  37. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Install the front door inside handle sub-assembly LH with the 4 screws.

  38. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side)

    Click here

  39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Driver Side)


    1. B004C33

      Connect the connector.

    2. B004CSX

      Connect the front door lock remote control cable assembly LH for the front door inside handle sub-assembly LH.

    3. B004CJLC01
      B004B1M Install in this Direction

      Insert the front door trim board sub-assembly LH into the front door panel to set the front door panel sub-assembly LH.

    4. Attach the clips to install the front door trim board sub-assembly LH.

    5. B004BMQ

      Install the 2 screws.

  40. INSTALL COURTESY LIGHT ASSEMBLY LH (for Driver Side)

    Click here

  41. INSTALL FRONT DOOR TRIM COVER SUB-ASSEMBLY LH (for Driver Side)


    1. Attach the clips to install the front door trim cover sub-assembly LH.

  42. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)

    Click here

  43. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY RH (for Front Passenger Side)


    1. B004AAT

      Connect the connector.

    2. B004AOD

      Connect the front door lock remote control cable assembly RH for the front door inside handle sub-assembly RH.

    3. B004B71C01
      B004B1M Install in this Direction

      Insert the front door trim board sub-assembly RH into the front door panel to set the front door panel sub-assembly RH.

    4. Attach the clips to install the front door trim board sub-assembly RH.

    5. Install the 3 screws.

  44. INSTALL COURTESY LIGHT ASSEMBLY RH (for Front Passenger Side)

    Click here

  45. INSTALL FRONT DOOR ASSIST GRIP ASSEMBLY RH (for Front Passenger Side)


    1. Attach the clips to install the front door assist grip assembly RH.

  46. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

    Note

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

    Click here

  47. INSTALL NO. 2 DECK BOARD

    Click here

  48. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  49. INSPECT POWER WINDOW OPERATION

    Click here

  50. CHECK SRS WARNING LIGHT

    Click here

  51. INSPECT DOOR LOCK OPERATION

    Click here