FRONT DOOR INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the LH side.

PROCEDURE


  1. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP LH


    1. A004QN8

      Attach the 7 clips to install the weatherstrip.

  2. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING LH

    Click here

  3. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING LH

    Click here

  4. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Click here

  5. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. A004TCUE02

      Attach the 16 clips to install the weatherstrip.

    2. Install the clip labeled A.

  6. INSTALL FRONT DOOR CHECK ASSEMBLY LH


    1. A004TV7

      Apply MP grease to the sliding areas of the door check.

    2. Install the door check to the door panel with the 2 nuts.

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

    3. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the bolt.

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

  7. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


    1. A004N76

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

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

  8. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. A004TOAE04

      Install the front door lock open rod as shown in the illustration.

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


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

    2. w/ Entry and Start System:


      1. A004PWC

        Attach the 2 clamps and 2 claws to attach the front door outside handle frame to the front door wire.

      2. A004TT6

        Attach the 2 claws to install the front door outside handle frame sub-assembly.

      3. Using a T30 "TORX" wrench, tighten the screw.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
      4. A004NBH

        Attach the 2 clamps.

    3. w/o Entry and Start System:


      1. A004NWG

        Attach the 2 claws to install the front door outside handle frame sub-assembly.

      2. Using a T30 "TORX" wrench, tighten the screw.

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

  10. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. A004O6W

      Install the front door inside locking cable assembly.

    2. A004NJW

      Attach the 3 claws.

  11. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. A004OOD

      Install the front door lock remote control cable.

  12. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

  13. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A004U9S

      Attach the 2 claws to install the pad.

  14. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A004T7M

      Attach the 3 claws to install the pad.

  15. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. w/ Entry and Start System:


      1. A004T1T

        Install the handle by pushing it in the direction of the arrow in the illustration.

      2. A004OD9E04
        Text in Illustration
        *1 Holder
        *2 Front Door Outside Handle Frame LH
        *3 Front Door Outside Handle Connector

        Attach the holder of the front door outside handle frame LH.

      3. A004U4KE05
        Text in Illustration
        *1 Connector Cover
        *2 Front Door Outside Handle Frame LH
        *3 Front Door Wire LH

        Connect the front door wire connector and attach the claw of the connector to the front door outside handle.

      4. A004SD5E05
        Text in Illustration
        *1 Connector Cover
        *2 Front Door Outside Handle Frame LH
        *3 Front Door Wire LH

        Attach the 2 claws to fix the connector cover in place.

    2. w/o Entry and Start System:


      1. A004PE1

        Install the handle by pushing it in the direction of the arrow in the illustration.

      2. A004T0LE05
        Text in Illustration
        *1 Holder
        *2 Front Door Outside Handle Frame LH

        Attach the holder of the front door outside handle frame LH.

  16. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (for Driver Side)


    1. A004R94

      Attach the 3 claws to install the front door outside handle cover to the front door lock key cylinder.

    2. A004SUJ

      Tighten the screw using a T30 "TORX" socket to install the cover (with the door lock key cylinder).

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

    3. Install the hole plug.

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


    1. Tighten the screw using a T30 "TORX" socket to install the cover.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A004N8S

      Install the hole plug.

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


    1. A004QTI

      Install the rear lower frame with the bolt.

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

  19. INSTALL FRONT DOOR BELT MOULDING LH

    Click here

  20. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP LH


    1. A004MRG

      Install the front door fix window weatherstrip to the front door fix window glass.

  21. INSTALL FRONT DOOR FIX WINDOW GLASS LH


    1. A004TEL

      Install the front door fix window glass together with the front door fix window weatherstrip in the direction indicated by the arrow in the illustration.

  22. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH


    1. A004O7T

      Insert the front door front lower frame sub-assembly from above and install it with the 3 bolts and screw.

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

  23. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY LH


    1. Apply MP grease to the sliding and rotating areas of the window regulator.

      Note

      Do not apply grease to the spring of the window regulator.

    2. A004OCJE01
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the temporary bolt onto the window regulator.

    3. Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.

      Note

      Be careful not to drop the window regulator as it may become damaged.

    4. Temporarily install the window regulator with the 5 bolts.

    5. Tighten the 6 bolts.

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

  24. INSTALL FRONT DOOR GLASS RUN LH


    1. A004TLC

      Install the front door glass run.

  25. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. A004MNRE02

      Insert the door glass into the door panel along the glass run as indicated by the arrows in the illustration.

      Note

      Be careful not to damage the glass.

    2. Install the door glass to the window regulator with the 2 bolts.

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

  26. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. Apply butyl tape to the door.

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

      Note


      • When installing the service hole cover, pull the links and connectors through the service hole cover.

      • There should be no wrinkles or folds after installing the service hole cover.

      • After installing the service hole cover, check the seal quality.

    3. A004OG0E02
      Text in Illustration
      *1 Reference Point

      Attach the front door service hole cover according to the reference points on the front door panel.

      Note

      Securely install the front door service hole cover preventing wrinkles and air bubbles.

    4. A004R3I

      for Power Seat:

      Attach the 3 clamps.

    5. A004SEM

      for Manual Seat:

      Attach the 2 clamps.

    6. Connect the 3 connectors.

  27. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  28. INSTALL OUTER MIRROR INSTALL HOLE COVER LH


    1. A004RKW

      Attach the 7 claws to install the outer mirror install hole cover.

  29. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  30. INSTALL DOOR FRAME GARNISH LH


    1. A004QYG

      Install the door frame garnish with the 2 clips.

  31. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. A004Q0T

      Install the front door inner glass weatherstrip.

  32. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. A004N3E

      Install the front door inside handle sub-assembly with the 8 claws.

  33. INSTALL SEAT MEMORY SWITCH (for Power Seat)


    1. A004R1E

      Attach the 2 claws to install the seat memory switch.

  34. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  35. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. A004OSW

      for Manual Seat:

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

    2. for Power Seat:


      1. A004RJ6

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

      2. Connect the connector.

      3. A004RT7

        Attach the wire harness.

    3. A004SAD

      Attach the front door trim board with the 5 claws of the front door inner glass weatherstrip.

    4. Connect the courtesy light connector.

    5. A004S6F

      Attach the 2 claws and 10 clips to install the trim board.

    6. Install the 3 screws.

  36. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. Install the front door No. 1 stiffener cushion.

  37. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)

    Click here

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

    Click here

  39. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)

    A004QB3E02
    *1 w/ Rear Door Power Window:
    *2 w/o Rear Door Power Window:

    1. Connect the connector.

    2. Attach the 7 claws and clip to install the front armrest base panel.

  40. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)

    Tech Tips

    Use the same procedure described for the driver side.

  41. INSTALL ASSIST GRIP COVER LH


    1. A004SVW

      Attach the 9 claws to install the assist grip cover.

  42. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


    1. A004T95

      Attach the 3 claws to install the inside handle bezel plug.

  43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.