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 to install the front door weatherstrip.

    2. Install the clip.

  5. INSTALL FRONT DOOR WEATHERSTRIP (for 3 Door)


    1. A01VINH

      Engage the 32 clips to 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. A01VLMAE02
      Text in Illustration
      *a Body Panel
      *b Door Panel

      Install the front door check assembly to 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 to 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. A01VJW2

      Engage the 2 claws and grommet to install the front door outside handle frame sub-assembly in the direction indicated by the arrow as shown in the illustration.

    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. A01VJW2

      Engage the 2 claws and grommet to install the front door outside handle frame sub-assembly in the direction indicated by the arrow as shown in the illustration.

    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 }
    5. A01VG43

      Engage the 2 clamps.

  10. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD


    1. A01VF57

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

  11. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD


    1. A01VHZQ

      Engage the 3 claws to 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 claw to 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 to 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 to 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.

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

    2. Install the screw.

      Note

      Make sure to return the front door weatherstrip to its original condition after performing this step.

  20. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A01VIB5

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

    2. Install 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


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

    2. A01VDO9E05
      Text in Illustration
      *a Temporary Bolt

      Install the temporary bolt to the front door window regulator sub-assembly.

    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 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 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.

  24. 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.

  25. 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.

  26. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

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

    Click here

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

    Tech Tips

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

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

    Tech Tips

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

  30. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Tech Tips

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

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

    Tech Tips

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

  32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Tech Tips

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

  33. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING

    Tech Tips

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

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


    1. A01VGPD

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

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


    1. A01VHWR

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

  36. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01VGDL

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

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


    1. A01VJGBE02
      Text in Illustration
      *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 to the front door inside handle sub-assembly.

    2. A01VE74

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

    3. A01VEXE

      Install the 3 screws.

    4. A01VIRV

      Engage the claw to close the cover.

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


    1. A01VJGBE02
      Text in Illustration
      *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 to the front door inside handle sub-assembly.

    2. A01VM0J

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

    3. A01VEXE

      Install the 3 screws.

    4. A01VIRV

      Engage the claw to close the cover.

  39. INSTALL FRONT ARMREST BASE UPPER PANEL


    1. Connect the connector.

    2. A01VDID

      Engage the clip, 8 claws and 4 guides to install the front armrest base upper panel.

  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  41. INSPECT SRS WARNING LIGHT

    Click here

  42. INSPECT POWER WINDOW OPERATION

    Click here