FRONT DOOR (w/ Power Window) REASSEMBLY

Tech Tips


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

  • The procedure described below is for the LH side.


  1. INSTALL FRONT DOOR CHECK ASSEMBLY

    A0136KF

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

    2. Apply adhesive to the screw.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a T40 "TORX" socket wrench, 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 (for 3 Door)

    A0138NZE02
    Text in Illustration
    *1 Clip

    1. Check that the ignition switch is turned to OFF.

    2. Check that the cable is disconnected from the negative battery terminal.

      CAUTION:

      After disconnecting the cable from the negative battery terminal, wait for at least 90 seconds before starting the operation.

    3. Check that the clip is securely engaged into the door panel.

    4. Install the side airbag sensor with the bolt.

      Torque:
      9.0 N*m  { 90 kgf*cm, 80 in.*lbf }

    5. Connect the side airbag sensor connector.

  3. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

    A01365R

    1. Install the front door No. 2 stiffener cushion with the 2 bolts.

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

  4. INSTALL DOOR LOCK CYLINDER AND KEY SET

    A01369S

    1. Install the door lock cylinder and key set in the direction shown in the illustration.

    2. A01366D

      Install the retainer in the direction indicated by the arrow in the illustration.

  5. INSTALL FRONT DOOR LOCK ACTUATOR ASSEMBLY

    A0136A5

    1. Install the front door lock actuator assembly with the 2 screws.

  6. INSTALL FRONT DOOR LOCK ASSEMBLY


    1. Apply MP grease to the sliding and rotating components of the front door lock assembly.

    2. A0138CA

      Apply adhesive to the threads of the 3 screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Install the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    5. A0137AW

      Connect the front door outside locking link, as shown in the illustration.

    6. A0138HL

      Connect the front door lock open rod, as shown in the illustration.

  7. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

    A01382L

    1. Install the front door outside handle assembly.

    2. A01368M

      Install the 2 nuts.

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

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

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

  8. 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. A0137UHE02

      Move the front door inside handle sub-assembly in the direction indicated by the arrow in the illustration. This will engage the 2 claws and allow the installation of the front door inside handle sub-assembly.

    3. Engage claw A.

      Text in Illustration
      *a Claw A

  9. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

    A0137QE

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

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

  10. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

    A0136H6

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

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

  11. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY


    1. Install the front door window regulator sub-assembly with the 3 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.

    2. Connect the connector.

  12. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

    A01382R

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

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

      Note

      Do not damage the front door glass.

    2. Install the hole plug.

  13. INSTALL FRONT DOOR GLASS RUN

    A0138IL

    1. Install the front door glass run.

  14. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP ASSEMBLY

  15. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY (for 5 Door)

    A01365KE01

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

    2. Remove the protective tape.

  16. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY (for 3 Door)

    A0137GYE01

    1. Engage the 6 claws and install the front door belt moulding.

    2. Remove the protective tape.

  17. 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.

  18. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

    A013718

    1. Engage the 2 clips and install the front door lower frame bracket garnish.

    2. Install the 2 screws.

  19. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

    A0136I0

    1. Install the front door front lower frame upper cover in the direction shown in the illustration.

  20. INSTALL FRONT DOOR NO. 2 SERVICE HOLE COVER

    A0138YK

    1. Apply butyl tape to the door.

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

      Tech Tips

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

  21. INSTALL FRONT DOOR SERVICE HOLE COVER

    A01362I

    1. Apply butyl tape to the door.

    2. Install a new front door service hole cover.

      Tech Tips

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

  22. INSTALL REAR NO. 3 SPEAKER ASSEMBLY


    1. Install the rear No. 3 speaker with the 6 screws.

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

    A0136OK

    1. Connect the connector.

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

    3. Install the screw.

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

    A01371G

    1. Connect the connector.

    2. Engage the 15 clips and install the front door trim board sub-assembly.

    3. Install the screw.

  25. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY


    1. A01390RE01

      Engage the 2 claws and install the power window regulator switch assembly.

  26. INSTALL FRONT ARMREST UPPER BASE PANEL

    A013832

    1. Connect the connector.

    2. A013827E01

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

  27. INSTALL ASSIST GRIP ASSEMBLY

    A0137X5E01

    1. Engage the 4 claws and install the assist grip assembly.

    2. Install the 2 screws.

  28. INSTALL DOOR ASSIST GRIP COVER

    A0137O5E01

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

  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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