FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the LH side.

  • Use the same procedure for RHD and LHD vehicles.

  • The procedures listed below are for LHD vehicles.

PROCEDURE


  1. INSTALL FRONT DOOR WEATHERSTRIP LH

    Tech Tips

    When installing the front door weatherstrip, heat the vehicle body and front door weatherstrip using a heat light.

    Standard
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Front Door Weatherstrip 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or front door weatherstrip excessively.


    1. w/ Spot Cover:


      1. Using a heat light, heat the vehicle body surface.

      2. Remove the double-sided tape from the vehicle body.

      3. Wipe off any tape adhesive residue with cleaner.

      4. Using a heat light, heat the vehicle body and a new front door weatherstrip LH.

      5. Remove the peeling paper from the face of the front door weatherstrip LH.

        Tech Tips

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

      6. Attach the 21 clips to install a new front door weatherstrip LH.

        Tech Tips


        • If clips are damaged during installation, replace them.

        • Press the front door weatherstrip LH firmly to install it.

    2. w/o Spot Cover:


      1. Attach the 21 clips to install the front door weatherstrip LH.

        Tech Tips

        If clips are damaged during installation, replace them.

  2. 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 }

  3. INSTALL FRONT NO. 2 DOOR STIFFENER CUSHION

    Tech Tips

    When installing the front No. 2 door stiffener cushion, heat the vehicle body and front No. 2 door stiffener cushion using a heat light.

    Standard
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Front No. 2 Door Stiffener Cushion 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or front No. 2 door stiffener cushion excessively.


    1. Clean the installation surface.


      1. Using a heat light, heat the vehicle body surface.

      2. Remove the double-sided tape from the vehicle body.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new front No. 2 door stiffener cushion.


      1. Using a heat light, heat the vehicle body and a new front No. 2 door stiffener cushion.

      2. Remove the peeling paper from the face of the front No. 2 door stiffener cushion.

        Tech Tips

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

      3. Attach the 2 clamps to install the door stiffener cushion.

        Tech Tips

        Press the front No. 2 door stiffener cushion firmly to install it.

      4. Install the 2 bolts.

  4. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. B001YD1E02

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

  5. INSTALL NO. 2 ELECTRICAL KEY WIRE HARNESS (w/ Entry and Start System)


    1. Attach the 2clamps and guide to install the No. 2 electrical key wire harness to the front door outside handle frame sub-assembly LH.

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


    1. Apply MP grease to the sliding areas of the front door outside handle frame sub-assembly LH.

    2. Attach the nut and 2 guides to install the front door outside handle frame sub-assembly LH.

    3. Attach the clamp.

    4. B001ZAFE03

      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 door panel.

  7. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. B001Y61

      Install the front door inside locking cable assembly LH.

    2. Attach the 3 claws.

  8. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the front door lock remote control cable assembly LH.

  9. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

  10. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH


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

  11. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH


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

  12. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B001WDL

      Pull and hold the bellcrank lever of the front door outside handle frame sub-assembly LH.

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

    3. w/ Entry and Start System:


      1. B001W3U

        Attach the 3 claws to install the connector and connector cover.

  13. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH


    1. Apply MP grease to the sliding and rotating areas of the front door lock cylinder.

    2. B001WIM

      Attach the 2 claws to install the front door outside handle cover LH to the front door lock cylinder.

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

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

    4. Install the hole plug.

  14. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

    Click here

  15. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. B001ZEUE19
      Text in Illustration
      *a Temporary Bolt

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

      Note

      Do not apply grease to the spring of the front door window regulator sub-assembly LH.

    2. Loosely install the temporary bolt onto the front door window regulator sub-assembly LH.

    3. Insert the front door window regulator sub-assembly LH into the door panel. Use the temporary bolt to hang the front door window regulator sub-assembly LH on the door panel.

      Note

      Be careful not to drop the front door window regulator sub-assembly LH as it may become damaged.

    4. Temporarily install the front door window regulator sub-assembly LH with the 5 bolts.

    5. Tighten the 6 bolts in the order shown in the illustration.

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

  16. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Click here

  17. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

    Click here

  18. INSTALL LOWER DOOR FRAME GARNISH LH


    1. Attach the clip and install a new lower door frame garnish LH.

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


    1. Attach the guide.

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

  20. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run LH.

  21. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. Temporarily install the multiplex network master switch assembly.

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

    3. Move the front door window regulator sub-assembly LH so that the front door glass sub-assembly LH bolts can be seen.

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

      CAUTION:


      • Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

      • If the airbag deploys for any reason, it may cause a serious accident.

      Note

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

    5. Disconnect the multiplex network master switch assembly.

    6. B001Z1L

      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.

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

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

  22. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. B001WFK

      Apply butyl tape to the door.

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

      Note


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

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

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

    3. B001ZLZE05

      Connect the 2 connectors.

    4. Attach the 9 clamps.

    5. Install the bolt as shown in the illustration.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  23. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH (w/ Curtain Shield Airbag)

    Click here

  24. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  25. INSTALL FRONT DOOR PANEL PROTECTOR LH


    1. Install the screw, and install the front No. 1 door stiffener cushion and front door panel protector LH.

  26. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Seat Position Memory System)

    Click here

  27. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  28. REMOVE FRONT DOOR WIRING SUB-ASSEMBLY


    1. Attach the 2 clamps to install the front door wiring sub-assembly to the front door inside handle bezel LH.

  29. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH


    1. Install the front door inside handle bezel LH to the trim board with the 8 screws.

  30. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the 2 claws to install the front door inside handle sub-assembly LH.

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

    Click here

  32. INSTALL FRONT INNER DOOR GLASS WEATHERSTRIP LH


    1. B001ZUN

      Attach the 4 claws to install the front inner door glass weatherstrip LH.

  33. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B001YXD

      Connect the connector.

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

    3. B001VQ2

      Attach the 4 claws and 13 clips to install the front door trim board sub-assembly LH.

    4. Install the 3 screws.

  34. INSTALL DOOR ASSIST GRIP COVER LH


    1. Attach the 8 claws to install the door assist grip cover LH to the front door trim board sub-assembly LH.

  35. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY

    Click here

  36. INSTALL FRONT UPPER ARMREST BASE PANEL LH

    Click here

  37. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH


    1. B001WMN

      Attach the 4 claws to install the front door inside handle bezel LH.

  38. INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)

    Click here

  39. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. Attach the clip and claw, and install the front door lower frame bracket garnish LH.

  40. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH (w/ Outside Moulding)

    Click here

  41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  42. CHECK SRS WARNING LIGHT

    Click here