FRONT DOOR(for Hatchback, Wagon) 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 (w/ Black Out Tape)

    Click here

  3. INSTALL NO. 1 BLACK OUT TAPE (w/ 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 LOWER FRAME GARNISH PAD


    1. Clean the front door panel sub-assembly.

    2. Remove the release paper from a new front door lower frame garnish pad.

      Tech Tips

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

    3. B004323C01
      *a Double-sided Tape

      Install a new front door lower frame garnish pad as shown in the illustration.

  7. INSTALL FRONT DOOR PANEL CUSHION


    1. B0044OG

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

  8. INSTALL FRONT DOOR DUST PROOF SEAL


    1. for 2-piece Type:


      1. B0042A7

        Engage the 4 claws to install 2 new front door dust proof seals.

    2. for 3-piece Type:


      1. B0041VH

        Engage the 6 claws to install 3 new front door dust proof seals.

  9. INSTALL DOOR WINDOW FRAME MOULDING CLIP


    1. B0042L9

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

  10. INSTALL DOOR FRAME GARNISH


    1. B0043KN

      Engage the clip to install a new door frame garnish.

  11. INSTALL FRONT DOOR WEATHERSTRIP


    1. B0044TH

      Engage the 16 clips and install the front door weatherstrip.

  12. 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.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B00437BN01

      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 }

  13. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B00423UN01

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

  14. 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. B00420EC01
      *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/ Smart Entry and Start System:


      1. B0043QW

        Engage the 3 clamps.

  15. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B0042B9

      Install the front door inside locking cable assembly.

    2. B0042VP

      Engage the 3 claws.

  16. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B0043KX

      Install the front door lock remote control cable assembly.

  17. INSTALL FRONT DOOR LOCK ASSEMBLY

    Note


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

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

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


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

    2. When reusing the front door lock assembly:


      1. B00431K

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

    3. B0042F7C01
      *1 Front Door Lock Open Rod

      Insert the front door lock open rod to the front door lock assembly.

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

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

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

    6. Connect the connector.

  18. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B0044FH

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

  19. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B0044Z3

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

  20. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B0043TC

      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/ Smart Entry and Start System:


      1. B0043T9

        Connect the connector.

      2. Engage the 2 claws.

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


    1. B0044TF

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

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


    1. B0044CG

      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. B00448F

      Install the hole plug.

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


    1. B00431V

      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. B0044YX

      Install the hole plug.

  24. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B0043GV

      Engage the guide.

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

  25. INSTALL FRONT DOOR GLASS RUN


    1. B0041UJ

      Install the front door glass run.

  26. 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. B0042VSC01
      *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.

  27. 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. B0044W8N01

      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. B0041X4

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

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

  28. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. B0044UWC02
      *a Reference Point

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

  29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

    Click here

  30. INSTALL FRONT SPEAKER COVER (w/o Front Speaker)


    1. B00449IC01
      *a Reference Point

      Attach the front speaker cover according to the reference points on the front door panel.

      Note

      Securely install the front speaker cover preventing wrinkles and air bubbles.

  31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (w/ Front No.1 Speaker)

    Click here

  32. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B00451N

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

  33. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B00447B

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

  34. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B0044ETC01
      *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. B0043RR

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

    3. B0042QA

      Install the 3 screws.

    4. B0044YC

      Engage the claw and close the cover.

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

    Click here

  36. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. w/ Front No. 2 Speaker:


      1. Connect the connector.

    2. B00438G

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

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


    1. Connect each connector.

    2. B0042IT

      Engage the 3 guides, 5 claws and clip, and install the power window regulator master switch assembly with front door armrest base panel.

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


    1. Connect the connector.

    2. B004341

      Engage the 3 guides, 5 claws and clip, and install the power window regulator switch assembly with front door armrest base panel.

  39. INSTALL DOOR ASSIST GRIP ASSEMBLY


    1. B0042LE

      Engage the guide and 11 clips and install the door assist grip assembly.

  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  41. 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

  42. 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