FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

  • 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.

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PROCEDURE


  1. INSTALL BACK DOOR CUSHION


    1. Attach the clip to install a new door panel cushion.

  2. REPAIR INSTRUCTION

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  3. INSTALL NO. 2 FRONT DOOR STRIPE LH

    Click here

  4. INSTALL FRONT DOOR OUTSIDE STRIPE LH

    Click here

  5. INSTALL NO. 1 BLACK OUT TAPE LH

    Click here

  6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Click here

  7. INSTALL FRONT DOOR BELT MOULDING LH

    Click here

  8. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. B001EIJ

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

  9. INSTALL FRONT DOOR CHECK ASSEMBLY LH


    1. B001HR3

      Install the front door check assembly LH to the front door panel assembly with the 2 nuts.

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

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Install the front door check assembly LH with the bolt.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  10. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


    1. Clean the installation surface.


      1. Using a heat light, heat the installation surface.

        Standard
        Item Temperature
        Vehicle body 40 to 60°C (104 to 140°F)

        Note

        Do not heat the vehicle body excessively.

      2. Remove the double-sided tape from the installation surface.

      3. Wipe off any tape adhesive residue with cleaner.

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


      1. Using a heat light, heat the front door No. 2 stiffener cushion and the installation surface.

        Tech Tips

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

        Standard
        Item Temperature
        Door stiffener cushion 20 to 30°C (68 to 86°F)
        Vehicle body 40 to 60°C (104 to 140°F)

        Note

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

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

        Tech Tips

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

      3. Attach the 2 clamps and double-sided tape to install the front door No. 2 stiffener cushion.

        Tech Tips

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

      4. Install the 2 bolts.

  11. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. B001I8FN02

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

  12. INSTALL FRONT DOOR WIRE LH (w/ Smart Entry and Start System)


    1. B001CTA

      Attach the 4 clamps to install the front door wire LH.

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


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

    2. B001DST

      Attach the door handle nut and claw.

    3. Using a T30 "TORX" socket 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 }

    4. w/ Entry and Start System:


      1. B001HHW

        Attach the clamp.

      2. Connect the front door wire LH connector.

  14. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH


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

  15. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH


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

  16. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B001GKD

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

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

    3. B001IM6

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

    4. B001EC7

      Connect the connector.

    5. Attach the 2 claws.

  17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the front door inside locking cable assembly LH.

    2. Attach the 3 claws.

  18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


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

  19. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

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


    1. B001EZN

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B001FSW

      Install the hole plug.

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


    1. B001I6W

      Attach the claw to install the front door outside handle cover LH to the lock cylinder assembly.

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


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

      Tech Tips

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

    2. B001GCB

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    3. B001IK5

      Install the hole plug.

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


    1. B001HLP

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

  24. INSTALL DOOR FRAME GARNISH LH


    1. B001GIV

      Attach the clip to install a new door frame garnish LH.

  25. INSTALL FRONT DOOR GLASS RUN LH


    1. B001GR3

      Install the front door glass run LH.

  26. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

    Click here

  27. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


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

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

    3. B001EDEC03
      *1 Temporary Bolt

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

    4. Temporarily install the 5 bolts, and then tighten the temporary bolt and 5 bolts.

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    5. Connect the connector.

  28. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


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

    2. Connect the multiplex network master switch assembly and move the front door glass sub-assembly LH so that the door glass bolt installation locations can be seen.

    3. Disconnect the cable from the negative (-) battery terminal and multiplex network master switch assembly.

      CAUTION:

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

      Click here

    4. B001GWXN01

      Insert the front door glass sub-assembly LH into the front door panel along the front door glass run LH as indicated by the arrows in the order shown in the illustration.

    5. B001H1YN02

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

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

  29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

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  30. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. Apply new butyl tape to the front door panel assembly LH.

    2. B001CRJC03
      *a Reference Point

      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.

    3. Attach the front door service hole cover LH using the reference points on the front door panel assembly LH.

      Note


      • 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 seal quality.

      Note

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

    4. B001HVX

      Attach the 2 clamps.

    5. Install the bolt to the front door wire LH.

  31. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH

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  32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

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  33. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY LH (w/ Reverse Shift-linked Mirror)

    Click here

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

    Click here

  35. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. B001F1G

      Attach the guide and 2 claws to install the front door inside handle sub-assembly LH to the front door trim board sub-assembly LH.

    2. Install the 2 screws.

    3. B001GN5

      Install the 8 screws to the door assist grip assembly LH.

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

    Click here

  37. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side)


    1. Install the multiplex network master switch assembly with the 3 screws.

  38. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH (w/ Personal Light)

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  39. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY LH (w/ Personal Light)

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  40. INSTALL FRONT REFLEX REFLECTOR ASSEMBLY


    1. Attach the 2 claws to install the front reflex reflector assembly.

  41. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. B001G97

      Install the front door inner glass weatherstrip LH.

  42. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B001GVM

      Connect the front door lock remote control cable assembly LH and front door inside locking cable assembly LH.

    2. Connect the 2 connectors.

    3. w/ Seat Position Memory System:


      1. Connect the connectors.

    4. B001CX2C01
      *a Reference Boss

      Attach the reference boss and front door trim board sub-assembly LH by attaching the 4 claws of the front door inner glass weatherstrip LH as shown in the illustration.

    5. B001H4A

      Attach the 12 clips to install the front door trim board sub-assembly LH.

    6. Install the 3 screws.

  43. INSTALL ASSIST GRIP COVER LH


    1. B001E2B

      Attach the 8 claws to install the assist grip cover LH.

  44. INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL LH


    1. B001FW7

      Attach the 3 claws to install the No. 2 door inside handle bezel LH.

  45. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. Attach the 2 claws to install the front door lower frame bracket garnish LH.

  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  47. INITIALIZE POWER WINDOW CONTROL SYSTEM


    1. Initialize the power window.

      Click here

  48. CHECK SRS WARNING LIGHT


    1. Check the SRS warning light.

      Click here

  49. ADJUST SIDE TELEVISION CAMERA ASSEMBLY (w/ Side Monitor System)

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