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.

  • A bolt without a torque specification is shown in the standard bolt chart Click here.

PROCEDURE


  1. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP LH


    1. Install the front door No. 3 weatherstrip LH with the 3 clips.

  2. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY LH


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

      Torque:
      32.5 N*m  { 332 kgf*cm, 24 ft.*lbf }

      CAUTION:

      Be sure to perform this procedure with 2 or more persons as the part is very heavy.

  3. INSTALL FRONT DOOR WIRE LH


    1. A001D38

      Connect the connector.

  4. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. Attach the clips to install the front door weatherstrip LH.

      Tech Tips

      If clips are damaged during installation, replace them.

  5. INSTALL FRONT DOOR CHECK ASSEMBLY LH


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

    2. Install the front door check assembly LH 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:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  6. INSTALL DOOR CHECK COVER LH


    1. Install the door check cover LH.

  7. INSTALL FRONT DOOR LOWER FRAME GARNISH PAD LH


    1. Install the front door lower frame garnish pad LH with the 2 bolts.

  8. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


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

  9. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (for Front Door)


    1. Install the door electrical key oscillator to the outside front door handle frame with the screw.

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


    1. Install the lock open rod to the front door outside handle frame sub-assembly LH.

    2. Attach the 3 clamps and connect the connector.

    3. Using a T30 "TORX" wrench, install the front door outside handle frame sub-assembly LH with the screw.

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

      Note

      A cover should be inserted between the screw and the door panel.

    4. Attach the 2 wire harness clamps.

  11. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. A001CKY

      Install the front door inside locking cable assembly LH.

    2. A001DTC

      Attach the 3 claws.

  12. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. A001CWM

      Install the front door lock remote control cable assembly LH.

    2. A001E30

      Attach the claw.

  13. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

  14. INSTALL NO. 2 SEPARATION DOOR STIFFENER CUSHION


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

  15. INSTALL FRONT DOOR OUTSIDE HANDLE PAD FRONT


    1. Attach the 3 claws to install the front door outside handle pad front.

  16. INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR


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

  17. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A001DCT

      Pull and hold the bellcrank lever of the front door outside handle assembly LH as shown in the illustration.

    2. Install the front door outside handle assembly LH by pushing it in the direction of the arrow in the illustration.

      Note

      If the bellcrank lever is not pulled and held when installing the handle, the bellcrank lever will interfere with the handle and become damaged.

    3. Using a T30 ''TORX'' socket, install the screw.

    4. Connect the connector.

  18. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH


    1. Using a T30 ''TORX'' socket, install the front door outside handle cover LH (with the door key cylinder) with the screw.

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

    2. Install the hole plug.

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


    1. A001D17

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

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

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


    1. Install the front door front lower frame sub-assembly LH with the 2 bolts.

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

  21. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH


    1. Apply MP grease to the sliding and rotating areas of the power window regulator motor assembly LH.

    2. A001DTV

      Using a T25 ''TORX'' driver, install the power window regulator motor assembly LH with the 3 screws.

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

  22. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. A001B4WE05
      Text in Illustration
      *1 Temporary Bolt

      Apply MP grease to the sliding and rotating area of the front door window regulator sub-assembly LH.

      Note

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

    2. Temporarily install the temporary bolt to the front door window regulator sub-assembly LH.

    3. Install the window regulator with the 5 bolts and tighten the temporary bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

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

    4. Connect the connector.

  23. INSTALL FRONT DOOR BELT MOULDING SUB-ASSEMBLY LH


    1. Install the front door belt moulding sub-assembly LH with the 6 screws.

      Tech Tips

      Install the screws in the order shown in the illustration.

    2. Tighten the 5 belt line screws indicated by the arrows in the illustration.

      A001AOPE08

    3. Install a nose piece to an air riveter or hand riveter. Then insert the mandrel part of a new φ4 mm waterproof rivet into the nose piece.

    4. Using the air riveter or hand riveter, install the rivet shown in the illustration.

      A0018YAE01
      *1 Rivet (C)

      Tech Tips


      • The rivet labeled (C) is for fixing the front door belt moulding in place.

      • If the rivet cannot be cut, pull it once and cut it.

      Note


      • A001FDYE15

        Do not pry the rivet with the riveter as this will cause damage to the riveter and mandrel.

        Text in Illustration
        *1 Riveter
        *2 Mandrel
        *a INCORRECT
        *b CORRECT
      • A001C4EE17

        Confirm that the rivets are seated properly against the front door outside moulding.

      • Do not tilt the riveter when installing the rivet to the front door outside moulding.

      • Do not leave any space between the rivet head and front door outside moulding.

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT
      • A001C08E15

        Do not leave any space between the front door outside moulding and front door panel. Firmly hold together the 2 items while installing the rivet.

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT

  24. INSTALL FRONT DOOR WINDOW FRONT FRAME MOULDING LH

    Click here

  25. INSTALL FRONT DOOR BELT MOULDING END COVER REAR LH


    1. A0019QJE03
      Text in Illustration
      *1 Double-sided Tape

      Place double-sided tape on the front door belt moulding end cover rear LH as shown in the illustration.

    2. A001AJK

      Attach the claw to install the front door belt moulding end cover rear LH.

  26. INSTALL FRONT DOOR WEATHERSTRIP LH

    Click here

  27. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run LH.

  28. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. A001D3I

      Insert the front door glass sub-assembly LH 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 front door glass sub-assembly LH to the front door window regulator sub-assembly LH with the 2 bolts.

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

    3. Install the hole plug.

  29. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP LH


    1. Install the front door glass inner weatherstrip LH.

  30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  31. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. Apply new butyl tape to the door.

    2. A001CDLE01
      Text in Illustration
      *a Reference Point

      Install a new front door service hole cover LH using the reference points on the front door panel.

      Tech Tips


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

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

      • After attaching the service hole cover, check the sealing quality.

  32. INSTALL FRONT DOOR NO. 2 SERVICE HOLE COVER LH


    1. Apply new butyl tape to the door.

    2. A0019WQE01
      Text in Illustration
      *a Reference Point

      Install a new front door No. 2 service hole cover LH using the reference points on the front door panel.

      Tech Tips


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

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

      • After attaching the service hole cover, check the sealing quality.

  33. INSTALL FRONT MULTIPLEX NETWORK DOOR ECU LH


    1. Install the front multiplex network door ECU LH to the door panel with the 2 screws.

    2. Connect the 3 connectors.

  34. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  35. INSTALL DOOR FRAME GARNISH LH


    1. Install the door frame garnish LH with the 2 clips.

  36. INSTALL FRONT DOOR TRIM COVER LH


    1. Attach the 5 clips to install the front door trim cover LH.

    2. Install the cushion.

  37. INSTALL INDICATOR LIGHT COVER


    1. Install the indicator light cover.

  38. INSTALL INDICATOR LIGHT BRACKET


    1. Attach the 2 claws to install the indicator light bracket.

  39. INSTALL INDICATOR LIGHT ASSEMBLY


    1. Install the indicator light assembly with the screw.

    2. Connect the connector.

  40. INSTALL SEAT MEMORY SWITCH

    Click here

  41. INSTALL HEIGHT ADJUSTABLE ANCHOR SWITCH


    1. Attach the 2 claws to install the height adjustable anchor switch.

    2. Connect the connector.

  42. INSTALL COURTESY LIGHT ASSEMBLY


    1. A001BJL

      Attach the claw to install the courtesy light assembly.

    2. Connect the connector.

  43. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH


    1. Connect the connector.

    2. Attach the claw to install the front door inside handle illumination light assembly LH.

  44. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect the connector.

    2. A001CW6

      Connect the 2 cables to the inside handle.

    3. Attach the 13 clips to install the front door trim board sub-assembly LH.

    4. Install the 3 screws.

  45. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL


    1. Connect the connector.

    2. A0019ZB

      Attach the 2 claws to install the power window regulator master switch assembly with front door armrest base panel.

  46. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


    1. Attach the 3 claws to install the front door inside handle bezel plug LH.

  47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  48. INSTALL COWL TOP VENTILATOR LOUVER RH

    Click here

  49. CHECK SRS WARNING LIGHT

    Click here