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.

    Click here

  2. REPAIR INSTRUCTION

    Click here

  3. INSTALL NO. 1 BLACK OUT TAPE

    Click here

  4. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  5. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  6. INSTALL FRONT DOOR VENT SEAL


    1. B00443I

      Install the front door vent seal.

  7. INSTALL FRONT DOOR PANEL CUSHION


    1. B00442Z

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

  8. INSTALL DOOR WINDOW FRAME MOULDING CLIP


    1. B004240

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

  9. INSTALL DOOR FRAME GARNISH


    1. B0044PD

      Engage the clip to install a new door frame garnish.

  10. INSTALL FRONT DOOR WEATHERSTRIP


    1. B00424F

      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. B0043JTC02
      B0042CO Bolt (A)
      B0043VS 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. B0042PWN01

      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. B0043KFC01
      *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. B0044CS

        Engage the 3 clamps.

  14. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B0041PU

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

  15. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B0042TA

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

    2. B0042AX

      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. B0044WF

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

    3. B0044AYC01
      *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. B0041YG

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

  18. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B00424J

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

  19. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B0042E0

      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. B00435B

        Connect the connector.

      2. Engage the 2 claws.

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


    1. B0043E3

      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. B0043A2

      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. B0042RJ

      Install the hole plug.

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


    1. B0042N3

      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. B0041SC

      Install the hole plug.

  23. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B0044W3

      Engage the guide.

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

  24. INSTALL FRONT DOOR GLASS RUN


    1. B0043QN

      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. B0042OTC03
      *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. B00433MN01

      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. B00449S

      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. B0042FZC01
      *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

    Click here

  29. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  30. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B0043AQ

      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. B0042PU

      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. B0043CDC01
      *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. B0041XF

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

    3. B0042U1

      Install the 3 screws.

    4. B0044FU

      Engage the claw to close the cover.

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

    Click here

  34. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. w/ Front No. 2 Speaker:


      1. Connect the connector.

    2. B004239

      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. B00422P

      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. B0044EJ

      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. B00430C

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

  38. INSTALL DOOR ASSIST GRIP COVER


    1. B004529

      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.

    Click here

  40. INITIALIZE POWER WINDOW CONTROL SYSTEM


    • for Models with Jam Protection Function on 4 Windows: Click here


    • for Models with Jam Protection Function on Driver Door Window Only: Click here

  41. INSPECT POWER WINDOW OPERATION


    • for Models with Jam Protection Function on 4 Windows: Click here


    • for Models with Jam Protection Function on Driver Door Window Only: Click here