FRONT DOOR REASSEMBLY

Tech Tips


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

  • The procedure listed below is for the LH side.


  1. INSTALL FRONT DOOR CHECK ASSEMBLY

    A0137BD

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

    2. Apply adhesive to the 2 bolts and screw.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using "Torx" socket wrench T40, install the front door check assembly onto the body panel with the screw.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

    4. 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 }

  2. INSTALL SIDE AIRBAG SENSOR ASSEMBLY

    A0136MW

    1. Install the bolt.

      Torque:
      12.6 N*m  { 128 kgf*cm, 9 ft.*lbf }

    2. Connect the connector.

  3. INSTALL FRONT DOOR STIFFENER CUSHION NO. 2

    A01365R

    1. Install the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  4. INSTALL DOOR LOCK CYLINDER AND KEY SET

    A01369S

    1. Insert the door lock cylinder and key set into the hole from outside of the vehicle and install it.

    2. A01366D

      Install the bracket by moving it in the direction shown in the illustration.

  5. INSTALL FRONT DOOR LOCK ASSEMBLY

    A0136UV

    1. Apply adhesive to the 3 screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Apply MP grease to the sliding and rotating areas of the front door lock assembly.

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 42 in.*lbf }
    4. A01393K

      Insert a round bar through the hole in the plate of the door lock cylinder and key set.

    5. Secure the round bar with the door lock cylinder and key set by turning the fastening portion in the direction shown.

  6. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE

    A01382L

    1. Install the front door handle assembly outside onto the body side from outside of the vehicle.

    2. A01368M

      Install the 2 nuts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    3. A01370S

      Insert a round bar through the hole in the plate of the front door handle assembly outside.

    4. Secure the round bar with the front door handle assembly outside by turning the fastening portion in the direction shown.

  7. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

    A01362G

    1. Connect the cable to the front door inside handle sub-assembly by turning it in the direction shown in the illustration.

    2. A0137UHE01

      Move the front door inside handle sub-assembly in the direction indicated by the arrow mark in the illustration. This will engage the claws and allow the installation of the front door inside handle sub-assembly.

    3. Engage claw A.

  8. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER

    A0137QE

    1. Install the bolt and front door frame sub-assembly rear lower.

      Torque:
      6.1 N*m  { 62 kgf*cm, 54 in.*lbf }

  9. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER

    A0136H6

    1. Install the bolt and front door frame sub-assembly front lower.

      Torque:
      6.1 N*m  { 62 kgf*cm, 54 in.*lbf }

  10. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

    A0138M0

    1. Install the front door window regulator sub-assembly with the 4 nuts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note

      Do not drop the front door window regulator sub-assembly as it may be damaged.

  11. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

    A01382R

    1. Install the front door glass sub-assembly onto the window regulator with the 2 screws.

      Torque:
      2.8 N*m  { 29 kgf*cm, 25 in.*lbf }

  12. INSTALL FRONT DOOR GLASS RUN

    A0138IL

    1. Install the front door glass run.

  13. INSTALL FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY INNER

  14. INSTALL FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER

    A01365KE01

    1. Engage the 5 claws and install the front door belt moulding.

    2. Remove the protective tape.

  15. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    A0138TB

    1. Install the outer rear view mirror assembly LH with the 3 screws.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note


      • Do not tighten the screws to more than the specified torque.

      • Before tightening the screws to the specified torque, provisionally tighten the screws by hand to fit the threads. Do not remove and reinstall the screws more than twice, when reusing a mirror.

  16. INSTALL FRONT DOOR SERVICE HOLE COVER NO. 2

    A0138WH

    1. Apply butyl tape to the door.

    2. Install a new front door service hole cover No. 2.

      Tech Tips

      Remove all wrinkles and folds when attaching the front door service hole cover No. 2.

  17. INSTALL FRONT DOOR SERVICE HOLE COVER

    A0138PI

    1. Apply butyl tape to the door.

    2. Install a new front door service hole cover.

      Tech Tips

      Remove all wrinkles and folds when attaching the front door service hole cover.

  18. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

    A0137G6E01

    1. Engage the 2 clips and install the 2 screws.

  19. INSTALL FRONT DOOR FRONT LOWER FRAME COVER UPPER

    A0136I0

    1. Install the front door front lower frame cover upper by sliding it in the direction indicated by the arrow.

  20. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

    A013823E01

    1. Engage the 13 clips and install the front door trim board sub-assembly.

    2. Install the screw.

  21. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY

    A0136XPE01

    1. Open all the window glasses.

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

  22. INSTALL ASSIST GRIP ASSEMBLY

    A0137X5E01

    1. Engage the 4 claws and install the 2 screws.

  23. INSTALL DOOR ASSIST GRIP COVER

    A0137O5E01

    1. Engage the 2 claws and install the door assist grip cover.

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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