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.

  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is 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. Clean the vehicle body 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 the front door weatherstrip LH.


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

      2. 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.

      3. 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. 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 DOOR NO. 2 STIFFENER CUSHION

    Tech Tips

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


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

      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 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.

  4. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. B001ACXE06

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

  5. INSTALL NO. 2 ELECTRICAL KEY WIRE HARNESS


    1. Attach the 2 clamps 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. 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

    Click here

  8. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

    Click here

  9. INSTALL FRONT DOOR LOCK COVER SUB-ASSEMBLY LH

    Click here

  10. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

  11. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH


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

  12. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH


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

  13. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B0018PK

      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. B0019RW

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

  14. INSTALL FRONT DOOR OUTSIDE HANDLE COVER


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

    2. B001897

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

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

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

    4. Install the hole plug.

  15. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

    Click here

  16. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. B00187ZE21
      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. Temporarily 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 }

    6. Connect the connector.

  17. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Click here

  18. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

    Click here

  19. INSTALL LOWER DOOR FRAME GARNISH LH


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

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


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

  21. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run LH.

  22. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. for Driver Side:

      Temporarily install the multiplex network master switch assembly.

    2. for Passenger Side:

      Temporarily install the power window regulator switch assembly.

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

    4. Move the door glass until the bolts appear in the service holes.

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

    6. B0018CUE02

      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 }

  23. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. B001AOQ

      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 installing the front door service hole cover LH.

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

    3. B0019ORE06

      Connect the 2 connectors.

    4. Attach the 9clamps.

    5. Install the bolt as shown in the illustration.

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

  24. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH

    Click here

  25. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  26. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY

    Click here

  27. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  28. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the guide to install the front door inside handle sub-assembly LH with the 5 screws.

    2. Install the No. 1 door trim bracket LH with the screw.

    3. Install the front door upper trim panel LH with the 11 screws.

  29. INSTALL FRONT DOOR WIRING SUB-ASSEMBLY


    1. Connect the connector.

    2. Attach the 8 clamp to install the front door wiring sub-assembly.

  30. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH

    Click here

  31. INSTALL SEAT MEMORY SWITCH

    Click here

  32. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. B0018G2

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

  33. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B0018MR

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

    2. B0019JJ

      Connect the front door inside locking cable assembly LH to the front door trim board sub-assembly LH.

    3. Connect each connector.

    4. B0019SY

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

    5. Install the 2 screws.

  34. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


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

  35. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

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

    Click here

  37. INSTALL POWER WINDOW MASTER SWITCH ASSEMBLY WITH BEZEL (for Driver Side)

    Click here

  38. INSTALL FRONT UPPER ARMREST BASE PANEL LH (for Driver Side)


    1. Connect the connector.

    2. Attach the 6claws and 2 clips to install the front upper armrest base panel LH.

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

    Click here

  40. INSTALL POWER WINDOW SWITCH ASSEMBLY WITH BEZEL (for Passenger Side)

    Click here

  41. INSTALL FRONT UPPER ARMREST BASE PANEL RH (for Passenger Side)


    1. Connect the connector.

    2. Attach the 6 claws and 2 clips to install the front upper armrest base panel RH.

  42. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


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

  43. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH


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

  44. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  45. CHECK SRS WARNING LIGHT

    Click here

  46. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here