FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

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

  • The procedure listed below is for the LH side.

PROCEDURE


  1. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. Degrease the front door weatherstrip LH installation surface using non-residue solvent.

    2. Remove the peeling paper of the double-sided tape trying not to touch the adhesional surface.

    3. B004VXSC02
      B004VGX Double-sided Tape

      Attach the clip and install the new front door weatherstrip LH.

      Note

      Press the double-sided tape on the front door weatherstrip LH firmly to apply it.

  2. INSTALL FRONT DOOR PANEL CUSHION


    1. B004WA5

      Attach the claw and install a new front door panel cushion.

  3. INSTALL FRONT DOOR NO. 4 WEATHERSTRIP LH


    1. B004VYP

      Attach the clip and install the front door No. 4 weatherstrip LH.

  4. INSTALL FRONT DOOR CHECK ASSEMBLY LH


    1. Clean the threaded portion on the vehicle body with non-residue solvent.

    2. When reusing bolt:


      1. Clean the threaded portion on the bolt with non-residue solvent.

      2. Apply adhesive to the threads of the bolt.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. B004YU0C02
      B004SZX Nut
      B004UK4 Bolt

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

      Torque:
      Bolt
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

    Click here

  6. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

    Click here

  7. INSTALL FRONT DOOR LOCK COVER SUB-ASSEMBLY LH

    Click here

  8. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY LH

    Click here

  9. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH


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

    2. B004RQX

      Attach the 2 wire harness clamps and guide.

    3. B004RWNC01
      *A Outside
      *B Inside

      Attach the claw as shown in the illustration.

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

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

  10. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. B004YRAC01
      B004RMI Install in this Direction

      Install the front door lock open rod LH on the front door lock with motor assembly LH as shown in the illustration.

      Tech Tips

      Check that the front door lock open rod LH is securely attached to the front door lock with motor assembly LH.

    2. B004TWTC01
      B004RMI Install in this Direction (1)
      B004T3S Install in this Direction (2)

      Install the front door lock open rod LH to the front door outside handle frame sub-assembly LH and attach the snap of the front door outside handle as shown in the illustration.

  11. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B004TGNC01
      B004RMI Install in this Direction (1)
      B004T3S Install in this Direction (2)

      Attach the guide in the direction indicated by the arrow shown in the illustration.

    2. Attach the claw in the direction indicated by the arrow shown in the illustration to install the front door front outside handle pad.

  12. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B004T4SC01
      B004RMI Install in this Direction (1)
      B004T3S Install in this Direction (2)

      Attach the guide in the direction indicated by the arrow shown in the illustration.

    2. Attach the claw in the direction indicated by the arrow shown in the illustration to install the front door rear outside handle pad.

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


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

    2. B004TDLC01
      B004RMI Install in this Direction

      Attach the guide for the front door lock cylinder assembly LH in the direction indicated by the arrow.

    3. B004S7MC02
      *1 Plug Hole

      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 }

    4. Install the plug hole.

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


    1. B004X1IC01
      B004RMI Install in this Direction

      Attach the claw of the front door outside handle cover RH in the direction indicated by the arrow.

    2. B004WM5C02
      *1 Plug Hole

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

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

    3. Install the plug hole.

  15. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B004TACC01
      B004RMI Install in this Direction

      Install the front door outside handle assembly LH in the direction of the arrow shown in the illustration.

    2. B004W1VC01
      *1 Holder
      B004RMI Install in this Direction

      Attach the holder as shown in the illustration.

    3. B004Y29

      Connect the connector.

    4. B004VG6C01
      B004RMI Install in this Direction

      Attach the claw and close the connector cover as shown in the illustration.

  16. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY LH


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

    2. B004YMHC01
      B004RMI Install in this Direction

      Pull out the front door window regulator assembly LH from the service hole as shown in the illustration.

    3. B004X3SC01
      B004SZX Nut
      B004UK4 Connector

      Install the front door window regulator assembly LH with the 6 nuts in the order shown in the illustration.

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

      Note

      Do not damage the front door panel assembly with the front door window regulator assembly LH.

    4. Connect the connector.

  17. INSTALL FRONT DOOR REAR WINDOW FRAME LH


    1. B004SNR

      Attach the clip and install the front door rear window frame LH.

    2. Install the nose piece to an air riveter and insert the mandrel section of a new φ 4 mm rivet into the nose piece.

    3. B004TMKC01
      *1 Nose piece

      Press the rivets perpendicularly to the installation holes. Using the air riveter, install the front door rear window frame LH with the 4 rivets.

      Note

      Press the air riveter perpendicularly to the installation holes.

      Tech Tips

      Pull the trigger again to cut off the rivet if the rivet does not cut off.

  18. INSTALL FRONT DOOR NO. 2 GLASS RUN LH


    1. B004RGTC01
      B004RMI Install in this Direction

      Install the front door No. 2 glass run to the front door rear lower frame sub-assembly LH.

  19. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH


    1. B004VQ2C02
      B004RMI Install in this Direction

      Attach the claw and install the front door rear lower frame sub-assembly LH to the front door rear window frame LH.

    2. Install the bolt.

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

  20. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. B004TOF

      Connect the 3 front multiplex network door ECU LH connectors.

    2. B004RBL

      Connect the connector and temporarily install the front door trim board sub-assembly LH.

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

    4. Turn the power switch on (IG).

    5. Move the front door glass sub-assembly LH until the installation bolts can be seen.

    6. Turn the power switch off.

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

      CAUTION:


      • After disconnecting the cable from the negative (-) auxiliary battery terminal, wait for at least 90 seconds to start the operation.

      • If the airbag deploys for any reason, it may cause a serious accident.

      B004UM0

    8. Disconnect the connector and remove the front door trim board sub-assembly LH.

    9. Disconnect the 3 front multiplex network door ECU LH connectors.

    10. B004STBC01
      B004RMI Install in this Direction (1)
      B004T3S Install in this Direction (2)

      Temporarily install the front door glass sub-assembly LH to the front door window regulator assembly LH in the order shown in the illustration.

      Note

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

    11. B004VW7

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

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

      Note

      Check that the frame portion on the rear side of the front door glass sub-assembly LH is installed in the groove of the front door No. 2 glass run.

      B004TL1

  21. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING LH

    Click here

  22. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING LH

    Click here

  23. INSTALL DOOR GUIDE PROTECTOR


    1. B004W3K

      Install the 2 door guide protectors with the 2 clips.

  24. INSTALL FRONT DOOR FRONT GLASS RUN LH


    1. B004WMG

      Install the front door front glass run LH to the front pillar upper cover sub-assembly LH.

  25. INSTALL FRONT DOOR GLASS RUN LH


    1. B004WKD

      Install one part of the front door glass run LH to the front pillar upper cover sub-assembly LH as shown in the illustration.

  26. INSTALL FRONT PILLAR UPPER COVER SUB-ASSEMBLY LH


    1. B004S0NC01
      B004RMI Install in this Direction (1)
      B004T3S Install in this Direction (2)

      Slide the front door glass run LH in the direction indicated by the arrow shown in the illustration and temporarily install it together with the front pillar upper cover sub-assembly LH with the 2 bolts.

      Note

      Check that the frame portion on the front side of the front door glass sub-assembly LH is attached to the front door glass run LH.

      B004SBS
    2. B004R7OC01
      B004RMI Install in this Direction (1)
      B004T3S Install in this Direction (2)

      Install the front door glass run LH as shown in the illustration.

  27. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. B004TK7N01

      Tighten the front pillar upper cover sub-assembly LH with the 2 bolts so the front door glass sub-assembly LH is at the position shown in the illustration when it is raised.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      Standard Clearance
      Area Measurement
      a 3.0 to 5.4 mm (0.118 to 0.213 in.)

  28. INSTALL FRONT DOOR WINDOW FRAME MOULDING LH(CENTER PILLAR SIDE)

    Click here

  29. INSTALL FRONT DOOR REAR BELT MOULDING END COVER LH

    Tech Tips

    When installing the front door rear belt moulding end cover LH, heat the front door panel and front door rear belt moulding end cover LH using a heat light.

    Item Temperature
    Front Door Panel 40 to 60°C (104 to 140°F)
    Front Door Rear Belt Moulding End Cover LH 20 to 30°C (68 to 86°F)

    CAUTION:


    • Do not touch the heat light and heated parts.

    • Touching the heat light may result in burns.

    • Touching heated parts for a long time may result in burns.

    B004UGDC71
    *a Heated Part
    *b Heat Light

    1. Install a new front door rear belt moulding end cover LH.


      1. Using a heat light, heat a new front door rear belt moulding end cover LH and the front door panel surface.

      2. Remove the peeling paper from the face of the front door rear belt moulding end cover LH.

        Tech Tips

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

      3. B004UPHC01
        B004VGX Double-sided Tape

        Attach the clip and install the front door rear belt moulding end cover LH as shown in the illustration.

        Note

        Press the double-sided tape on the front door rear belt moulding end cover LH firmly to apply it.

  30. INSTALL FRONT DOOR BELT MOULDING LH

    Click here

  31. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH


    1. B004UNK

      Align the No. 2 front door weatherstrip with the groove of the front door window frame front moulding LH and install it.

  32. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP LH

    Tech Tips

    When installing the front door No. 3 weatherstrip LH, heat the front door panel and front door No. 3 weatherstrip LH using a heat light.

    Item Temperature
    Front Door Panel 40 to 60°C (104 to 140°F)
    Front Door No. 3 Weatherstrip LH 20 to 30°C (68 to 86°F)

    CAUTION:


    • Do not touch the heat light and heated parts.

    • Touching the heat light may result in burns.

    • Touching heated parts for a long time may result in burns.

    B004UGDC71
    *a Heated Part
    *b Heat Light

    1. Install a new front door No. 3 weatherstrip LH.


      1. Using a heat light, heat a new front door No. 3 weatherstrip LH and the front door panel surface.

      2. Remove the peeling paper from the face of the front door No. 3 weatherstrip LH.

        Tech Tips

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

    2. B004TE1C01
      B004VGX Double-sided Tape

      Attach the 4 clips and install the front door No. 3 weatherstrip LH.

      Note

      Press the double-sided tape on the front door No. 3 weatherstrip LH firmly to apply it.

  33. INSTALL FRONT DOOR ARMREST SET BRACKET LH


    1. Install the 2 screw grommets.

    2. B004XPU

      Install the front door armrest set bracket LH with the 3 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  34. INSTALL DOOR SIDE AIR BAG SENSOR LH

    Click here

  35. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  36. INSTALL FRONT MULTIPLEX NETWORK DOOR ECU LH


    1. B004TO2C02
      B004SZX Screw
      B004UK4 Connector

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

    2. Connect the clamp and 3 connectors.

  37. INSTALL OUTER MIRROR INSTALL HOLE COVER LH

    Click here

  38. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. B004WIGC01
      B004RMI Install in this Direction

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

    2. B004RF0

      Attach the clip and install the front door service hole cover LH.

    3. B004XLIC01
      B004RMI Turn
      B004SZX Service Hole Cover Clip

      Turn the clips 45° in the direction indicated by the arrow shown in the illustration and install the 4 front door weatherstrip clips.

    4. Connect the connector.

    5. Connect the wire harness clamps.

  39. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  40. INSTALL FRONT DOOR PANEL PROTECTOR LH


    1. B004W5WC01
      B004RMI Install in this Direction

      Install the front door panel protector LH to the front door glass inner weatherstrip LH as shown in the illustration.

  41. INSTALL FRONT DOOR VENT SEAL LH


    1. B004YIUC01
      B004RMI Install in this Direction

      Install the front door vent seal LH as shown in the illustration.

  42. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP LH


    1. B004SLWC01
      B004RMI Install in this Direction

      Install the front door glass inner weatherstrip LH in the direction indicated by the arrow shown in the illustration.

  43. INSTALL UPPER DOOR FRAME GARNISH LH


    1. B004T80C01
      B004RMI Install in this Direction

      Attach the guide in the direction indicated by the arrow shown in the illustration and install the upper door frame garnish LH.

    2. Attach the clip.

  44. INSTALL FRONT DOOR TRIM COVER LH


    1. Attach the 2 clips to the front door panel LH.

    2. B004R3DC01
      B004RMI Install in this Direction

      Slide the front door trim cover LH in the direction indicated by the arrow shown in the illustration and attach the clip.

    3. B004V25

      Attach the clip and install the front door trim cover LH.

  45. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. B004UCY

      Install the front door inside handle sub-assembly LH with the 3 screws.

  46. INSTALL SEAT MEMORY SWITCH LH

    Click here

  47. INSTALL NO. 2 SWITCH BEZEL

    Click here

  48. INSTALL FRONT DOOR INNER TRIM COVER LH


    1. B004T0X

      Attach the claw and install the front door inner trim cover LH.

  49. INSTALL FRONT DOOR LOCK CONTROL KNOB HOLDER LH


    1. B004WMI

      Attach the claw and install the front door lock control knob holder LH to the door lock control knob bezel.

  50. INSTALL DOOR LOCK CONTROL KNOB BEZEL LH


    1. B004UQDC01
      B004RMI Install in this Direction

      Attach the claw and install the door lock control knob bezel LH together with the front door lock control knob holder LH.

  51. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

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

    Click here

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

    Click here

  54. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect each connector.

    2. B004X3ZC01
      B004RMI Install in this Direction

      Attach the claw and connect the front door inside locking cable assembly LH.

    3. B004RT5C01
      B004RMI Install in this Direction

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

    4. B004XK8C01
      B004RMI Install in this Direction

      Attach the claw in the direction indicated by the arrow shown in the illustration to install the front door trim board sub-assembly LH.

    5. B004VERC01
      B004RMI Install in this Direction

      Attach the clip and install the front door trim board sub-assembly LH.

    6. Install the 3 screws.

  55. INSTALL FRONT DOOR NO. 2 ARMREST COVER LH


    1. B004X50

      Insert the guide, attach the claw and install the front door No. 2 armrest cover LH.

  56. INSTALL FRONT DOOR ARMREST COVER LH


    1. B004XC3

      Attach the claw and install the front door armrest cover LH.

  57. INSTALL FRONT DOOR TRIM UPPER COVER LH


    1. B004Y2L

      Attach the claw and install the front door trim upper cover LH.

  58. INSPECT FITTING OF FRONT DOOR

    Click here

  59. INSPECT FITTING OF FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. Remove the front door inner trim cover LH.

    2. B004SQ9

      Rotate the dial to align the instrument panel safety pad sub-assembly stitching with the stitch line on the front door trim board sub-assembly LH as shown in the illustration.

      Tech Tips

      Adjust the front door trim board sub-assembly LH so that it is within the range of -2.0 to 2.0 mm (-0.079 to 0.079 in.).

    3. Install the front door inner trim cover LH.

  60. 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

  61. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY

    Click here

  62. SRS WARNING LIGHT

    Click here

  63. PERFORM DIAGNOSTIC SYSTEM CHECK

    Click here

  64. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  65. CHECK POWER WINDOW CONTROL SYSTEM

    Click here

  66. CHECK POWER DOOR LOCK CONTROL SYSTEM

    Click here

  67. INSPECT OUTER REAR VIEW MIRROR OPERATION

    Click here

  68. CHECK FRONT POWER SEAT CONTROL SYSTEM

    Click here