FRONT DOOR REASSEMBLY

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 with 4 new clips.

    2. Install the front door panel with the 4 bolts.

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

      CAUTION:

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

    3. Connect the front door wire to the front door panel with the 2 bolts.

    4. Attach the 8 clamps of the front door wire.

  2. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH

    Click here

  3. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER LH

    Click here

  4. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Click here

  5. INSTALL FRONT DOOR REAR BELT MOULDING END COVER LH

    Click here

  6. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. Attach the 17 clips to install the front door weatherstrip.

  7. INSTALL FRONT DOOR CHECK ASSEMBLY LH


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

    2. When reusing a bolt:


      1. Clean the threads of the bolt with non-residue solvent.

      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 with the 2 nuts and bolt.

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

  8. INSTALL FRONT DOOR DUST PROOF SEAL

    Tech Tips

    Use the same procedure for all front door dust proof seals.


    1. Attach the claw to install a front door dust proof seal.

  9. INSTALL FRONT DOOR PANEL CUSHION


    1. Install a new front door panel cushion.

  10. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH


    1. Attach the 9 clips to install the front door No. 2 weatherstrip.

  11. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. Install the front door lock open rod to the front door outside handle frame.

    2. A000NNKE02
      Text in Illustration
      *1 Snap

      Rotate the snap in the direction indicated by the arrow in the illustration to attach the snap to the front door lock open rod.

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


    1. Apply MP grease to the sliding area of the front door outside handle frame.

    2. Attach the 2 clamps of the front door wire to the front door outside handle frame.

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

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

  13. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


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

  14. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


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

  15. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. Apply MP grease to the sliding area of the front door outside handle.

    2. A000QBC

      Install the front door outside handle by moving it in the direction indicated by the arrow shown in the illustration.

    3. A000QAQE02
      Text in Illustration
      *1 Holder

      Attach the holder in the direction indicated by the arrow in the illustration.

    4. Attach the claw of the connector to connect the connector.

    5. Attach the 2 claws of the connector cover to connect the connector cover.

  16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the front door inside locking cable.

    2. Attach the 3 claws to close the cover.

  17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the front door lock remote control cable.

  18. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

  19. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY


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

  20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH


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

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

    2. Install the hole plug.

  21. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

    Tech Tips

    When installing the front door No. 2 stiffener cushion, heat the front door panel using a heat light.

    Standard
    Item Temperature
    Front Door Panel 40 to 60°C (104 to 140°F)

    Note

    Do not heat the front door panel excessively.


    1. Clean the front door panel surface.


      1. Using a heat light, heat the front door panel surface.

      2. Remove the double-sided tape from the front door panel.

      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 panel.

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

        Tech Tips

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

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


    1. Attach the guide to install the front door rear lower frame.

    2. Install the 2 bolts.

  23. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  24. INSTALL OUTER MIRROR PROTECTOR


    1. Clean the front door panel surface.


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

      2. Wipe off any tape adhesive residue with cleaner.

    2. A000OKDE02
      Text in Illustration
      *a Reference Point

      Install a new outer mirror protector.


      1. Remove the peeling paper from the face of the outer mirror protector.

        Tech Tips

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

      2. Install the outer mirror protector using the reference points on the front door panel.

        Tech Tips


        • Press the outer mirror protector firmly to install it.

        • Securely install the outer mirror protector to prevent wrinkles and air bubbles.

        • There should be no wrinkles or folds after installing the outer mirror protector.

        • After installing the outer mirror protector, check the seal quality.

  25. INSTALL FRONT MULTIPLEX NETWORK DOOR ECU LH


    1. Install the front multiplex network door ECU with the 2 bolts.

    2. Connect the 3 connectors.

  26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


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

    2. Temporarily install the temporary bolt to the front door window regulator.

    3. A000NKUE02
      Text in Illustration
      *1 Temporary Bolt

      Install the front door window regulator with the 5 bolts, and then tighten the temporary bolt.

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

      Note

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

    4. Connect the connector.

  27. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

    Click here

  28. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run.

  29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. Temporarily install the power window regulator master switch assembly with front door armrest base panel.

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

    3. Operate the front door window regulator so that the front door glass can be installed.

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

      Note

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

    5. Remove the power window regulator master switch assembly with front door armrest base panel.

    6. A000OTKE03

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

    7. Install the front door glass with the 2 bolts.

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

  30. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

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


    1. A000NBQE02
      Text in Illustration
      *a Reference Point

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

      Tech Tips


      • Securely install the front door No. 2 service hole cover to prevent wrinkles and air bubbles.

      • There should be no wrinkles or folds after installing the front door No. 2 service hole cover.

      • After installing the front door No. 2 service hole cover, check the seal quality.

  32. INSTALL FRONT DOOR SERVICE HOLE COVER LH


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

    2. A000OOGE02
      Text in Illustration
      *a Reference Point

      Pass the front door inside locking cable and front door lock remote control cable through a new front door service hole cover, and then attach the front door service hole cover using the reference points on the front door panel.

      Tech Tips


      • Securely install the front door service hole cover to prevent wrinkles and air bubbles.

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

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

  33. INSTALL FRONT DOOR ARMREST SET BRACKET LH


    1. Install the front door armrest set bracket with the 2 screws.

  34. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. Install the front door inner glass weatherstrip.

  35. INSTALL DOOR FRAME GARNISH LH


    1. Attach the 2 clips to install the door frame garnish.

  36. INSTALL FRONT DOOR TRIM COVER LH


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

  37. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


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

  38. INSTALL FRONT DOOR TRIM SEAL LH


    1. Attach the 11 clips to install the front door trim seal.

  39. INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY LH


    1. Attach the 3 claws to install the front door trim ornament to the No. 1 interior illumination light.

  40. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the claw to install the front door inside handle.

    2. Install the screw.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Install the front door inside handle together with the front door trim ornament and No. 1 interior illumination light with the 15 screws.

  41. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH

    Click here

  42. INSTALL SEAT MEMORY SWITCH

    Click here

  43. INSTALL SWITCH BEZEL

    Click here

  44. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


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

    2. Connect each connector.

    3. A000OLLE01
      Text in Illustration
      *1 Reference Boss

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

    4. Attach the reference boss in the direction indicated by the arrow in the illustration.

    5. Attach the 9 clips to install the front door trim board.

    6. Install the 3 screws.

  45. INSTALL FRONT DOOR HOLE COVER


    1. Install the front door hole cover.

  46. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  47. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


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

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


    1. Connect the connector.

    2. Attach the 5 claws and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.

  49. ADJUST FRONT DOOR PANEL SUB-ASSEMBLY LH

    Click here

  50. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  51. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  52. CHECK POWER WINDOW CONTROL SYSTEM

    Click here

  53. CHECK POWER DOOR LOCK CONTROL SYSTEM

    Click here

  54. CHECK OUTER REAR VIEW MIRROR

    Click here

  55. CHECK SEAT MEMORY SWITCH


    1. for LHD:

      Click here

    2. for RHD:

      Click here

  56. CHECK SRS WARNING LIGHT

    Click here