FRONT DOOR REASSEMBLY

PROCEDURE


  1. APPLY BODY GREASE

  2. INSTALL NO. 1 BLACK OUT TAPE (for 5 Door)

    Tech Tips

    Use the same procedure as for the LH side Click here.

  3. INSTALL FRONT DOOR PANEL CUSHION


    1. A01VEJQ

      Install the 2 front door panel cushions.

  4. INSTALL FRONT DOOR WEATHERSTRIP (for 5 Door)


    1. A01VKOQ

      Engage the 29 clips and install the front door weatherstrip.

    2. Install the clip.

  5. INSTALL FRONT DOOR WEATHERSTRIP (for 3 Door)


    1. A01VINH

      Engage the 32 clips and install the front door weatherstrip.

    2. Install the clip.

  6. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. A01VLMA

      Install the front door check assembly onto the door panel with the 2 bolts.

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

    3. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the front door check assembly onto the body panel with the bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  7. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A01VFR0E01
      Text in Illustration
      *1 Snap

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

  8. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Entry and Start System)


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

    2. A01VJW2E03
      Text in Illustration
      *1 Grommet

      Slide the front door outside handle frame sub-assembly to install it.

    3. Engage the grommet and 2 claws.

    4. A01VESA

      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 }

  9. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Entry and Start System)


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

    2. A01VJW2E03
      Text in Illustration
      *1 Grommet

      Slide the front door outside handle frame sub-assembly to install it.

    3. Engage the grommet and the 2 claws.

    4. A01VESA

      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 }
    5. A01VG43

      Engage the 2 clamps.

  10. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD


    1. A01VF57

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

  11. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD


    1. A01VHZQ

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

  12. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Entry and Start System)


    1. A01VM29

      Pushing the front door outside handle assembly in the direction of the arrow mark shown in the illustration, install the front door outside handle assembly.

  13. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Entry and Start System)


    1. A01VM29

      Pushing the front door outside handle assembly in the direction of the arrow mark shown in the illustration, install the front door outside handle assembly.

    2. Connect the connector.

    3. A01VDUH

      Engage the 3 claws and clamp.

  14. INSTALL FRONT DOOR LOCK ASSEMBLY

    Click here

  15. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (w/ Lock Cylinder)


    1. A01VFZD

      Engage the 2 guides and the claw and install the front door outside handle cover.

    2. A01VIGB

      Temporarily install the front door outside handle cover.

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

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

    4. Install the hole plug.

  16. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (w/o Lock Cylinder)


    1. A01VG2M

      Engage the 2 claws and temporarily install the front door outside handle cover.

    2. A01VICT

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

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

    3. Install the hole plug.

  17. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP


    1. Install the front door fix window weatherstrip onto the front door fix window glass.

  18. INSTALL FRONT DOOR FIX WINDOW GLASS


    1. A01VDUE

      Slide the front door fix window glass, in the direction indicated by the arrow in the illustration, to install it.

  19. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. A01VI7O

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

      Torque:
      Bolt
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  20. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A01VIB5

      Engage the guide.

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

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  21. INSTALL FRONT DOOR GLASS RUN


    1. A01VF7G

      Install the front door glass run.

  22. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/ Power Window)


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

    2. A01VDO9E06
      Text in Illustration
      *1 Temporary Bolt

      Install the temporary bolt.

    3. Insert the front door window regulator sub-assembly into the door panel. Use the temporary bolt to hang the front door window regulator sub-assembly on the door panel.

    4. Tighten the 3 bolts and the temporary bolt in the order shown in the illustration.

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

    5. Install the front door window regulator sub-assembly with the 2 bolts.

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

    6. Connect the connector.

  23. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/o Power Window)


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

    2. A01VIWOE04
      Text in Illustration
      *1 Temporary Bolt

      Install the temporary bolt.

    3. Insert the front door window regulator sub-assembly into the door panel. Use the temporary bolt to hang the front door window regulator sub-assembly on the door panel.

    4. Tighten the 2 bolts and temporary bolt in the order shown in the illustration.

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

    5. Install the front door window regulator sub-assembly with the 2 bolts.

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

  24. INSTALL FRONT DOOR GLASS NO. 1 CHANNEL FILLER


    1. Apply soapy water to a new front door glass channel filler.

    2. A01VLN9E02
      Text in Illustration
      *a Front Side
      *b Rear Side
      *c

      87.7 mm

      (3.453 in.)
      *d

      84.3 mm

      (3.319 in.)

      Install a new front door glass channel No. 1 filler as shown in the illustration.

  25. INSTALL FRONT DOOR GLASS NO. 1 CHANNEL


    1. Apply soapy water to a front door glass No. 1 channel.

    2. A01VKUME02
      Text in Illustration
      *a Front Side
      *b Rear Side
      *c

      87.7 mm

      (3.453 in.)
      *d

      84.3 mm

      (3.319 in.)

      Using a plastic-faced hammer, tap the front door glass No. 1 channel onto the front door glass sub-assembly to install the glass channel.

      Note


      • Be careful not to damage the front door glass sub-assembly or front door glass No. 1 channel.

      • Make sure the position of the front door glass No. 1 channel filler does not change.

  26. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the power window regulator master switch and move the front door glass sub-assembly so that the door glass bolt holes can be seen.

    3. Disconnect the cable from the negative (-) battery terminal and the power window regulator master switch.

    4. A01VIQNE02

      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.

      Note

      Do not damage the front door glass sub-assembly.

    5. A01VJVA

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. A01VJWN

      Install the front door service hole cover.

  27. INSTALL FRONT DOOR SERVICE HOLE COVER (for 5 Door)


    1. Apply butyl tape to the front door panel.

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

    3. A01VGM2E02
      Text in Illustration
      *a Reference Point

      Install a new front door service hole cover according to the reference points on the front door panel.

      Tech Tips

      Securely install the front door service hole cover taking care to prevent wrinkles.

  28. INSTALL FRONT DOOR SERVICE HOLE COVER (for 3 Door)


    1. Apply butyl tape to the front door panel.

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

    3. A01VDS9E02
      Text in Illustration
      *a Reference Point

      Install a new front door service hole cover according to the reference points on the front door panel.

      Tech Tips

      Securely install the front door service hole cover taking care to prevent wrinkles.

  29. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  30. INSTALL DOOR SIDE AIRBAG SENSOR (for 3 Door)

    Click here

  31. INSTALL FRONT FENDER NO. 1 STRIPE (w/ Stripe Tape)

    Tech Tips

    Use the same procedure as for the LH side Click here.

  32. INSTALL FRONT DOOR OUTSIDE MOULDING (w/ Outside Moulding)

    Tech Tips

    Use the same procedure as for the LH side Click here.

  33. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side Click here.

  34. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING (for 3 Door)

    Tech Tips

    Use the same procedure as for the LH side Click here.

  35. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side Click here.

  36. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING

    Tech Tips

    Use the same procedure as for the LH side Click here.

  37. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP (for 5 Door)


    1. A01VEL2

      Engage the 7 claws and install the front door glass inner weatherstrip as shown in the illustration.

  38. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP (for 3 Door)


    1. A01VJTN

      Engage the 8 claws and install the front door glass inner weatherstrip as shown in the illustration.

  39. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01VJK6

      Engage the 4 guides and install the front door inside handle sub-assembly.

  40. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for 5 Door)


    1. A01VM8LE04
      Text in Illustration
      *1 Front Door Lock Remote Control Cable Assembly
      *2 Front Door Inside Locking Cable Assembly

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

    2. A01VFK7

      Engage the 7 clips and install the front door trim board sub-assembly.

    3. A01VFLS

      Install the 3 screws.

    4. A01VHR5

      Engage the claw and close the cover.

  41. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for 3 Door)


    1. A01VM8LE04
      Text in Illustration
      *1 Front Door Lock Remote Control Cable Assembly
      *2 Front Door Inside Locking Cable Assembly

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

    2. A01VGBZ

      Engage the 8 clips and install the front door trim board sub-assembly.

    3. A01VFLS

      Install the 3 screws.

    4. A01VHR5

      Engage the claw and close the cover.

  42. INSTALL FRONT ARMREST BASE UPPER PANEL (w/ Power Window)


    1. Connect the connector.

    2. A01VF0R

      Engage the 9 claws and the 4 guides and install the front armrest base upper panel.

  43. INSTALL FRONT ARMREST BASE UPPER PANEL (w/o Power Window)


    1. Connect the connector.

      Tech Tips

      If the front armrest base upper panel is equipped with door lock switch, connect the connector.

    2. A01VFL0

      Engage the 7 claws and the 3 guides, and install the front armrest base upper panel.

  44. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)


    1. A01VGGKE01
      Text in Illustration
      *a Inside of Vehicle

      Install the window regulator handle plate.

    2. Open the all windows.

    3. A01VK6EE01
      Text in Illustration
      *a Assemble with Glass in Fully Open Position

      Install the front door window regulator handle assembly with the clip at the angle shown in the illustration.

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  46. INSPECT SRS WARNING LIGHT (w/ VSC)

    Click here

  47. INSPECT SRS WARNING LIGHT (w/o VSC)

    Click here

  48. INSPECT POWER WINDOW OPERATION (w/ Power Window)

    Click here