FRONT DOOR(for Sedan) REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for both the RH and LH sides.

  • The procedure described below is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition 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.

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  2. REPAIR INSTRUCTION

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  3. INSTALL NO. 1 BLACK OUT TAPE

    Click here

  4. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

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  5. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

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  6. INSTALL FRONT DOOR VENT SEAL


    1. A012I6O

      Install the front door vent seal.

  7. INSTALL FRONT DOOR PANEL CUSHION


    1. A012HJP

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

  8. INSTALL DOOR WINDOW FRAME MOULDING CLIP


    1. A012HGA

      Engage the 2 claws to install a new door window frame moulding clip.

  9. INSTALL DOOR FRAME GARNISH


    1. A012FW5

      Engage the clip to install a new door frame garnish.

  10. INSTALL FRONT DOOR WEATHERSTRIP


    1. A012JHM

      Engage the 16 clips and install the front door weatherstrip.

  11. 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 (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A012J8KC02
      A012M0O Bolt (A)
      A012L0C Bolt (B)

      Install the front door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      Bolt (B)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  12. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A012GQAN01

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

  13. 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. A012K6DC01
      *A Outside
      *B Inside

      Engage the 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 }

    4. w/ Entry and Start System:


      1. A012G5V

        Engage the 3 clamps.

  14. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A012N0B

      Install the front door inside locking cable assembly as shown in the illustration.

  15. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A012FLF

      Install the front door lock remote control cable assembly as shown in the illustration.

    2. A012G04

      Engage the 2 claws as shown in the illustration.

  16. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

    Note


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

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

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


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

    2. When reusing the front door lock with motor assembly:


      1. A012JAP

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

    3. A012ISCC01
      *1 Front Door Lock Open Rod

      Connect the front door lock open rod to the front door lock with motor assembly.

      Tech Tips

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

    4. Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    5. Connect the connector.

  17. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A012LLZ

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

  18. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A012JD0

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

  19. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A012J0Q

      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. w/ Entry and Start System:


      1. A012JIS

        Connect the connector.

      2. Engage the 2 claws.

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


    1. A012LA4

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

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


    1. A012FU1

      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 }
    2. A012HTX

      Install the hole plug.

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


    1. A012FEZ

      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. A012FW0

      Install the hole plug.

  23. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A012KZR

      Engage the guide.

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

  24. INSTALL FRONT DOOR GLASS RUN


    1. A012H0O

      Install the front door glass run.

  25. 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. A012GX2C03
      *a 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.

  26. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. for Driver Side:


      1. 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. for Front Passenger Side:


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

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

    5. for Driver Side:


      1. Disconnect the power window regulator master switch assembly.

    6. for Front Passenger Side:


      1. Disconnect the power window regulator switch assembly.

    7. A012J0SN01

      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.

    8. A012IVD

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

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

  27. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. A012MX9C01
      *a Reference Point

      Pass the front door lock remote control cable assembly, front door inside locking cable assembly and each connector 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.

  28. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

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  29. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  30. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A012K0G

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

  31. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A012G8I

      Engage the 4 guides to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

  32. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A012IB2C01
      *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. A012JHV

      Engage the 8 clips and install the front door trim board sub-assembly as shown in the illustration.

    3. A012L1O

      Install the 3 screws.

    4. A012KPR

      Engage the claw to close the cover.

  33. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (w/ Front No. 2 Speaker)

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  34. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. w/ Front No. 2 Speaker:


      1. Connect the connector.

    2. A012K5V

      Engage the 2 guides and clip to install the front door lower frame bracket garnish.

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


    1. Connect each connector.

    2. A012J99

      Engage the 5 guides, 6 claws and clip to install the power window regulator master switch assembly with front door armrest base panel.

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


    1. Connect the connector.

    2. A012G8G

      Engage the 5 guides, 6 claws and clip to install the power window regulator switch assembly with front door armrest base panel.

  37. INSTALL FRONT ARMREST ASSEMBLY


    1. A012G5X

      Engage the 5 claws and 2 clips to install the front armrest assembly.

  38. INSTALL DOOR ASSIST GRIP COVER


    1. A012LLK

      Engage the 10 claws to install the door assist grip cover.

  39. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  40. INITIALIZE POWER WINDOW CONTROL SYSTEM

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  41. INSPECT POWER WINDOW OPERATION

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