FRONT DOOR REASSEMBLY

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

    Click here

  3. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  4. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  5. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

    Click here

  6. REPAIR INSTRUCTION

    Click here

  7. INSTALL FRONT DOOR REAR OUTSIDE STRIPE

    Click here

  8. INSTALL FRONT DOOR OUTSIDE STRIPE

    Click here

  9. INSTALL NO. 1 DOOR TRIM PAD

    Tech Tips

    If a No. 1 door trim pad is torn and the front door panel is exposed, replace it with a new one.


    1. Clean the front door panel sub-assembly surface.


      1. Remove the double-sided tape from the front door panel sub-assembly.

      2. Wipe off any tape adhesive residue.

    2. Remove the release paper from 2 new No. 1 door trim pads.

      Tech Tips

      After removing the release paper, keep the exposed adhesive free from foreign matter.

    3. Align the cutouts on each No. 1 door trim pad with the upper edge of the front door panel and the spot welds as shown in the illustration and temporarily install the 2 No. 1 door trim pads as shown in the illustration.

      B001MUME02
      Text in Illustration
      *a Spot Weld *b Cutout
      Standard Measurement:
      Area Measurement Area Measurement
      a 5.0 mm (0.197 in.) or less b 4.0 mm (0.157 in.) or less
    4. B001M3E

      Install the 2 No. 1 door trim pads as shown in the illustration.

  10. INSTALL DOOR DUST PROOF SEAL


    1. B001LPY

      Install the door dust proof seal.

  11. INSTALL FRONT DOOR PANEL CUSHION


    1. B001MRJ

      Engage the 2 claws to install 2 new front door panel cushions.

  12. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. B001MHA

      Engage the 8 clips to install the front door No. 2 weatherstrip.

  13. INSTALL FRONT DOOR WEATHERSTRIP


    1. B001KZ2E02
      Text in Illustration
      *1 Double-sided Tape

      Engage the 20 clips and install a new front door weatherstrip.

  14. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B001L0F

      Install the front door check assembly with the bolt and 2 nuts.

      Torque:
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  15. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B001LHKE02

      Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

  16. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. B001NC8

      Engage the door handle nut and claw.

    3. 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 }

  17. INSTALL FRONT DOOR WIRE


    1. B001L9X

      Engage the 5 clamps and install the front door wire.

    2. Connect the connector.

  18. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B001LTT

      Install the front door inside locking cable assembly.

    2. B001LLN

      Engage the 3 claws.

  19. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B001MLL

      Install the front door lock remote control cable assembly.

  20. INSTALL FRONT DOOR LOCK ASSEMBLY

    Note


    • When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.

    • Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.

    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock assembly.


    1. Apply MP grease to the sliding parts of the front door lock assembly.

    2. B001LWO

      Install a new door lock wiring harness seal to the front door lock assembly.

    3. B001MP6E03
      Text in Illustration
      *1 Front Door Lock Open Rod

      Insert the front door lock open rod to the front door lock assembly.

    4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.

    5. Using a 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 }

    6. Connect the connector.

  21. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B001MG1

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

  22. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B001LYM

      Engage the 3 claws and install the front door front outside handle pad.

  23. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B001LK5

      Insert the front end of the front door outside handle assembly into the front door outside handle frame.

    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame, then slide the front door outside handle assembly toward the front of the vehicle to install it.

    3. B001MBX

      Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

    4. B001LXG

      Connect the connector.

    5. Engage the 2 claws.

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


    1. B001LSE

      Engage the claw and 2 guides, and install the front door outside handle cover to the front door lock cylinder as shown in the illustration.

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


    1. B001KBQ

      Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B001MZ9

      Install the hole plug.

  26. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)


    1. B001LGN

      Install the front door outside handle cover with lock cylinder assembly.

      Tech Tips

      Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

    2. B001N3Z

      Using a T30 "TORX" socket wrench, install the front door lock cylinder with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. B001N6Z

      Install the hole plug.

  27. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B001L2O

      Engage the guide.

    2. Install the front door rear lower frame sub-assembly with the bolt as shown in the illustration.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  28. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION


    1. When reusing the No. 2 front door stiffener cushion:


      1. Clean the No. 2 front door stiffener cushion.

      2. Remove the double-sided tape from the No. 2 front door stiffener cushion.

      3. Wipe off any tape adhesive residue with cleaner.

      4. B001KR2E02

        Apply new double-sided tape to the No. 2 front door stiffener cushion as shown in the illustration.

        Area Dimension
        (A) 80.0 mm (3.150 in.)
        (B) 20.0 mm (0.787 in.)
        (C) 4.0 mm (0.157 in.)

    2. Clean the front door panel sub-assembly.

    3. B001KWNE02
      Text in Illustration
      *1 Double-sided Tape

      Engage the 2 guides.

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

  29. INSTALL FRONT DOOR GLASS RUN


    1. B001M6Z

      Install the front door glass run.

  30. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the power window regulator motor.


    1. B001KZX

      Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws.

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

      Tech Tips

      A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  31. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


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

    2. Install the temporary bolt to the front door window regulator assembly.

    3. B001MHIE04
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the front door window regulator assembly.

    4. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

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

    5. Connect the connector.

  32. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. Connect the cable to the negative (-) battery terminal.

    2. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

    3. Disconnect the cable from the negative (-) battery terminal.

      Note

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

    4. Disconnect the power window regulator master switch assembly.

    5. B001L1DE02

      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.

    6. B001N4GE02

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

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    7. B001KM6

      Install the grommet.

  33. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the front door panel.

    2. B001KJBE02
      Text in Illustration
      *1 Reference Point

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

    3. 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.

  34. INSTALL FRONT DOOR TRIM BRACKET (for Driver Side)


    1. B001KRP

      Install the front door trim bracket with the 2 screws.

  35. INSTALL FRONT DOOR TRIM BRACKET (for Front Passenger Side)


    1. B001L97

      Install the front door trim bracket with the 2 screws.

  36. INSTALL WIRING HARNESS CLAMP BRACKET (w/o Memory)


    1. B001M2E

      Install the wiring harness clamp bracket with the 2 screws.

    2. Engage the clamp.

  37. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  38. INSTALL OUTER MIRROR PROTECTOR

    Click here

  39. INSTALL OUTER MIRROR INSTALL HOLE COVER

    Click here

  40. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)

    Click here

  41. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  42. INSTALL DOOR FRAME GARNISH


    1. B001N6W

      Engage the clip to install a new door frame garnish.

  43. INSTALL FRONT DOOR TRIM SEAL


    1. B001M5D

      Engage the 8 clips to install the front door trim seal.

  44. INSTALL FRONT DOOR WIRING SUB-ASSEMBLY (w/ Seat Position Memory System)


    1. B001KEO

      Engage the 3 clamps and install the front door wiring sub-assembly.

  45. INSTALL SEAT MEMORY SWITCH (w/ Seat Position Memory System)

    Click here

  46. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B001MNR

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

  47. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B001MEN

      Engage the claw and 2 guides, and install the front door inside handle sub-assembly to the front door trim board sub-assembly as shown in the illustration.

  48. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for Driver Side)


    1. B001LDOE02
      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.

    2. w/ Seat Position Memory System:


      1. Connect the connector.

    3. B001LRB

      Engage the 11 clips and install the front door trim board sub-assembly.

    4. Install the 2 screws.

    5. Remove the protective tape.

  49. INSTALL DOOR ARMREST COVER (for Driver Side)


    1. B001LNU

      Install the door armrest cover.

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


    1. Connect the connector.

    2. B001N9B

      Engage the 2 guides, 3 clips and 7 claws, and install the power window regulator master switch assembly with front door armrest base panel.

  51. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for Front Passenger Side)


    1. B001LQVE02
      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.

    2. B001LN0

      Engage the 11 clips and install the front door trim board sub-assembly.

    3. Install the 2 screws.

    4. Remove the protective tape.

  52. INSTALL DOOR ASSIST GRIP ASSEMBLY (for Front Passenger Side)


    1. B001N6Y

      Engage the 3 guides and install the door assist grip assembly.

    2. Install the 2 screws.

  53. INSTALL DOOR ASSIST GRIP COVER (for Front Passenger Side)

    Note

    If a type A door assist grip cover was installed, make sure to replace it with a new type B door assist grip cover.

    B001M52C01
    *A for Type A *B for Type B
    *a Clip *b Claw (Transparent)

    1. B001MK7

      Engage the guide and 4 claws to install the door assist grip cover.

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


    1. Connect the connector.

    2. B001M8G

      Engage the 4 guides, 3 clips and 8 claws, and install the power window regulator switch assembly with front door armrest base panel.

  55. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B001LQH

      Engage the clip and claws, and install the front door lower frame bracket garnish.

  56. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B001MBG

      Engage the 3 claws and install the front door inside handle bezel plug.

  57. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  58. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

  59. INSTALL DECK FLOOR BOX RH

    Click here

  60. INSTALL REAR NO. 3 FLOOR BOARD

    Click here

  61. INSTALL REAR DECK FLOOR BOX

    Click here

  62. INSTALL REAR NO. 2 FLOOR BOARD

    Click here

  63. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here