FRONT DOOR (for TMMK Made) REASSEMBLY

Tech Tips

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PRECAUTION

Note

After turning the engine 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.

REPAIR INSTRUCTION

Clean the vehicle body surface.

Using a heat light, heat the vehicle body surface.

Heating Temperature
Item	Temperature
Vehicle Body	40 to 60°C (104 to 140°F)

Note

Do not heat the vehicle body excessively.

Wipe off any tape adhesive residue with cleaner.

Installation temperature
1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.
  Tech Tips
  - The most appropriate temperature for installing the tape is 25°C (77°F).
  - When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases.
Before installation
1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.
  
  Tech Tips
  
  Spray water on the shop floor to settle any dust.
Key points for handling the tape
1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.
  
  Note
  
  Do not bend the tape or leave it in high temperature places.

Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)

Note

Position the tape accurately to achieve a neat finish and to avoid peeling.
The tape cannot be reused because it deforms and will not fit any more after being removed.

To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 3 to 7 cm (1.18 to 2.76 in.) per second.

Text in Illustration
*A	Pressing Forward	*B	Pulling
*1	Non-padded Side	*2	Padded Side
*3	Squeegee	*4	Black Out Tape
*5	Release Paper	-	-
*a	Side View	-	-

Reference Measurement
Area	Measurement
A	10 to 20 mm (0.393 to 0.787 in.)
B	30 to 70 mm/sec. (1.18 to 2.76 in./sec.)
C	40 to 50° (for pressing forward)
D	30 to 45° (for pulling)

Note

Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

Tech Tips

Either angle of the squeegee (pressing forward or pulling) is acceptable.
Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.

Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces)

Text in Illustration
*1	Squeegee
*2	Hem
*a	First
*b	Second
*c	Third

If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.

Tech Tips

When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

Key points for installation of the tape (how to use a squeegee and installation procedure for corners)
1. Remove the release paper and apply the tape carefully with your fingers.
2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.
Check after installation
1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.
  
  Note
  
  Do not reuse the tape.

INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

Refer to the illustration to position the front door lower outside stripe.

Text in Illustration
*A	LH Side	*B	RH Side
*a	Edge of Curved Surface	*b	Square
*c	Round	-	-

Standard Measurement
Dimension	Measurement
A	1.5 mm (0.0591 in.)
B	1.0 mm (0.0394 in.)

Remove the release paper and apply the stripe.

INSTALL FRONT DOOR STRIPE

Refer to the illustration to position a new front door stripe.

Text in Illustration
*A	LH Side	*B	RH Side
*a	Edge of Curved Surface	*b	Square
*c	Round	-	-

Standard Measurement
Dimension	Measurement
A	1.5 mm (0.0591 in.)
B	1.0 mm (0.0394 in.)

Remove the release paper and apply the stripe.

INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

Engage the claw and guide of the front door upper window frame moulding to the door frame.

Using an air riveter or hand riveter with a nose piece, install the front door upper window frame moulding with 7 new rivets.

Tech Tips

If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

Note

Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

Text in Illustration
*a	Riveter
*b	Mandrel
*c	Incorrect

Confirm that the rivets are seated properly against the moulding.

Text in Illustration
*a	Riveter
*b	Incorrect

Do not tilt the riveter when installing the rivet to the moulding.
Do not leave any space between the rivet head and moulding.

Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

Text in Illustration
*a	Riveter
*b	Incorrect

INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

Tech Tips

When installing a new front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light.

Heating Temperature
Item	Temperature
Vehicle Body	40 to 60°C (104 to 140°F)
Front Door Rear Window Frame Moulding	20 to 30°C (68 to 86°F)

Note

Do not heat the vehicle body or front door rear window frame moulding excessively.

Clean the vehicle body surface.
1. Using a heat light, heat the vehicle body surface.
2. Remove any remaining double-sided tape from the vehicle body.
3. Wipe off any tape adhesive residue with cleaner.
Using a heat light, heat the vehicle body and a new front door rear window frame moulding.
Remove the release paper from the front door rear window frame moulding.

Tech Tips

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

Text in Illustration
*a	Caulking Sponge
	Double-sided Tape

Engage the clip and guide, and attach the double-sided tape to install the front door rear window frame moulding.

INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
1. Engage the 5 claws to install the front door belt moulding assembly.
INSTALL DOOR DUST PROOF SEAL
1. Text in Illustration
  
  *A for Front Side
  
  *B for Rear Side
  
  Install the 2 door dust proof seals.
INSTALL FRONT DOOR PANEL CUSHION
1. Engage the 2 claws to install 2 new front door panel cushions.
INSTALL FRONT DOOR NO. 2 WEATHERSTRIP
1. Engage the 8 clips to install the front door No. 2 weatherstrip.
INSTALL DOOR FRAME GARNISH
1. Engage the clip to install a new door frame garnish.
INSTALL FRONT DOOR WEATHERSTRIP
1. Engage the 19 clips and install the front door weatherstrip.
INSTALL FRONT DOOR CHECK ASSEMBLY
1. Apply MP grease to the sliding parts of the front door check assembly.
2. Clean the bolt hole on the vehicle body.
3. Clean the bolt threads of the bolt.
4. Apply adhesive to the threads of the bolt.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
5. Install the front door check assembly with the 3 bolts.
  
  Torque:
  
  Bolt (A)
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  
  Bolt (B)
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
INSTALL FRONT DOOR LOCK OPEN ROD
1. Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.
INSTALL FRONT DOOR WIRE
1. Engage the 3 clamps to install the front door wire.

Text in Illustration
*A	for Front Side
*B	for Rear Side

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.

Text in Illustration
*A	Outside
*B	Inside
*1	Door Handle Nut

Engage the claw.

Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw and door handle nut.

Torque:

4.0 N*m { 41 kgf*cm, 35 in.*lbf }
Engage the 3 clamps.
Connect the connector.

INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY
1. Install the front door inside locking cable assembly as shown in the illustration.
2. Engage the 3 claws.
INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
1. Install the front door lock remote control cable assembly as shown in the illustration.
INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY
Note
- When reusing the 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. Install a new door lock wiring harness seal to the front door lock with motor assembly.
3. Text in Illustration
  
  *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 }
INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Engage the 2 claws to install the front door rear outside handle pad.
INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Engage the 3 claws to install the front door front outside handle pad.
INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY
1. Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.
2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame sub-assembly, then slide the front door outside handle assembly toward the front of the vehicle to install it.
3. Connect the connector.
4. Engage the 2 claws.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)
1. Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
1. 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. Install the hole plug.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)
1. 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. Install the hole plug.
INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
1. Engage the guide as shown in the illustration.
2. Install the front door rear lower frame sub-assembly with the 2 bolts.
INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY
1. Engage the guide as shown in the illustration.
2. Install the front door front lower frame sub-assembly with the 2 bolts.
INSTALL FRONT DOOR GLASS RUN
1. Install the front door glass run.
INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION
1. Clean the front door panel sub-assembly.
2. Text in Illustration
  
  *a Double-sided Tape
  
  Engage the 2 guides.
3. Install a new No. 2 front door stiffener cushion with the 2 bolts.
INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY
Note

The regulator arm must be below the intermediate position when installing the front power window regulator motor assembly.
1. Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
  
  Tech Tips
  
  When replacing a front power window regulator motor assembly, a new front power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.
INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY
1. Apply MP grease to the sliding parts of the front door window regulator assembly.
2. Temporarily install the temporary bolt to the front door window regulator assembly.
3. Text in Illustration
  
  *a Temporary Bolt
  
  Temporarily install the front door window regulator assembly with the 5 bolts.
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 }
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.
  2. Disconnect the power window regulator master switch assembly.
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.
  2. Disconnect the power window regulator switch assembly.
4. Disconnect the cable from the negative (-) battery terminal.
  
  CAUTION:
  
  Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
  
  Note
  
  When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
5. 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.
  
  Note
  
  Do not damage the front door glass sub-assembly.
6. Install the front door glass sub-assembly with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
7. Install the grommet.
INSTALL NO. 2 FRONT DOOR SERVICE HOLE SEAL
1. Install the No. 2 front door service hole seal.
INSTALL NO. 1 FRONT DOOR SERVICE HOLE SEAL
1. Install the No. 1 front door service hole seal.
INSTALL FRONT DOOR SERVICE HOLE COVER
1. Apply new butyl tape to the front door panel.
2. Text in Illustration
  
  *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. Install 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.
4. Engage the 5 clamps.
5. Install the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
6. Connect each connector.
INSTALL OUTER REAR VIEW MIRROR ASSEMBLY
1. Engage the clip.
2. Engage the claw to temporarily install the outer rear view mirror assembly.
3. Install the 3 bolts.
  
  Tech Tips
  
  Tighten the bolts in the order shown in the illustration.
  
  Torque:
  
  11 N*m { 107 kgf*cm, 8 ft.*lbf }
4. Connect the connector.
5. Install the outer rear view mirror assembly with the clip.
INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

Note

Do not touch the speaker cone.
1. Engage the 2 claws to the vehicle body to temporarily install the front No. 1 speaker assembly.
2. Text in Illustration
  
  *A LH Side
  
  *B RH Side
  
  Install the front No. 1 speaker assembly with the 4 screws.
  
  Tech Tips
  
  Install the screws in the order shown in the illustration.
3. Connect the connector.

Text in Illustration
*1	Front Door Lock Open Rod

Text in Illustration
*a	Double-sided Tape

Text in Illustration
*a	Temporary Bolt

Text in Illustration
*a	Reference Point

Text in Illustration
*A	LH Side
*B	RH Side

INSTALL DOOR SIDE AIRBAG SENSOR

Check that the engine switch is off.
Check that the cable is disconnected from the negative (-) battery terminal.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Text in Illustration

*a Incorrect *b Correct
Insert the pin (stopper) into the door hole and install the door side airbag sensor to the front door panel with the bolt.

Torque:

9.0 N*m { 92 kgf*cm, 80 in.*lbf }
Note
- If the door side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one.
- When installing the door side airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts.
- Make sure that the pin (stopper) is securely inserted into the body hole.
- Tighten the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

Text in Illustration
*a	Incorrect	*b	Correct

Connect the connector to the door side airbag sensor.

Note

When connecting any airbag connector, take care not to damage the airbag wire harness.

Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).

Text in Illustration
*1	White Housing Lock	*2	Yellow CPA
*a	Connection is Completed	-	-

Tech Tips

When engaged, the white housing lock will slide. Be sure not to hold the white housing lock and part (A), as it may result in an insecure fit.

Check that there is no looseness in the installation parts of the door side airbag sensor.

INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
1. Engage the 3 clips to install the front door lower frame bracket garnish.
INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP
1. Install the front door inner glass weatherstrip.
INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Engage the 2 claws and guide to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

Text in Illustration
*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 as shown in the illustration.

Engage the clamp.
Text in Illustration

*a Reference Boss

Engage the 4 claws and reference boss as shown in the illustration.
Engage the 10 clips to install the front door trim board sub-assembly.
Install the 3 screws.

INSTALL COURTESY LIGHT ASSEMBLY
1. Connect the connector.
2. Text in Illustration
  
  *A for LH Side
  
  *B for RH Side
  
  Engage the claw to install the courtesy light assembly.
INSTALL FRONT ARMREST ASSEMBLY
1. Engage the 2 guides, 3 clips and 7 claws to install the front armrest assembly.
INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)
1. Connect each connector.
2. Engage the 3 guides, 2 clips and 6 claws to install the power window regulator master switch assembly with front door armrest base panel.
INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)
1. Connect each connector.
2. Engage the 3 guides, 2 clips and 6 claws to install the power window regulator switch assembly with front door armrest base panel.
INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER
1. Engage the 2 guides and 2 claws to install the front door front lower frame upper cover.
INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG
1. Engage the 3 claws to install the front door inside handle bezel plug.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INITIALIZE POWER WINDOW CONTROL SYSTEM

Click here
INSPECT POWER WINDOW OPERATION

Click here
INSPECT SRS WARNING LIGHT

Click here