FRONT DOOR (for TMC, TMMR Made) REASSEMBLY

Tech Tips


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

  • The procedure described below is for the LH side.


  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


    1. Clean the vehicle body surface.


      1. 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.

      2. Wipe off any tape adhesive residue with cleaner.

    2. 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.

    3. 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.

    4. 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.

    5. 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.


      1. 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.

        B000H3LE02
        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.

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


      1. B000LZSE09
        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.

    7. 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.

    8. 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.

  3. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE


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

      B000IVQE01
      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.)

    2. Remove the release paper and apply the stripe.

  4. INSTALL FRONT DOOR STRIPE


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

      B000HSVE01
      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.)

    2. Remove the release paper and apply the stripe.

  5. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING


    1. B000MX3

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

    2. 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


      • B000M8QE09

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

        Text in Illustration
        *1 Riveter
        *2 Mandrel
        *a Incorrect
      • B000LVPE10

        Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding.

        Text in Illustration
        *1 Riveter
        *a Incorrect
      • B000LUHE12

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

        Text in Illustration
        *1 Riveter
        *a Incorrect

  6. 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)
    Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or front door rear window frame moulding 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. B000JPQE01
      Text in Illustration
      *1 Double-sided Tape
      *2 Caulking Sponge

      Install a new front door rear window frame moulding.


      1. Using a heat light, heat the vehicle body and front door rear window frame moulding.

      2. Remove the release paper from the face of the front door rear window frame moulding.

        Tech Tips

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

      3. Install the front door rear window frame moulding with the clip.

  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY


    1. B000L79

      Engage the 6 claws to install the front door belt moulding assembly.

  8. INSTALL FRONT DOOR VENT SEAL


    1. B000M7L

      Install the front door vent seal.

  9. INSTALL FRONT DOOR PANEL CUSHION


    1. B000MNV

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

  10. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. B000MPO

      Engage the 8 clips to install the front door No. 2 weatherstrip.

  11. INSTALL DOOR FRAME GARNISH


    1. B000M2I

      Engage the clip to install a new door frame garnish.

  12. INSTALL FRONT DOOR WEATHERSTRIP


    1. B000HTF

      Engage the 19 clips and install the front door weatherstrip.

  13. 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. B000K6WE01

      Install the front door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Bolt (B)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  14. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B000M24E01

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

  15. INSTALL FRONT DOOR WIRE (w/ Smart Entry and Start System)


    1. B000NAD

      Engage the 3 clamps to install the front door wire.

  16. 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. B000JDYE01
      Text in Illustration
      *1 Door Handle Nut
      *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 and door handle nut.

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

    4. w/ Smart Entry and Start System:


      1. B000JIV

        Engage the 3 clamps.

      2. Connect the connector.

  17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. B000NI3

      Install the front door inside locking cable assembly.

    2. B000II5

      Engage the 3 claws.

  18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B000LM9

      Install the front door lock remote control cable assembly.

  19. 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 on the connector with a new one.

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

    • 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 with motor lock 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. B000HW4

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

    3. B000IHFE01
      Text in Illustration
      *1 Front Door Lock Open Rod

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

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

    5. 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 }

  20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B000NJ0

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

  21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B000LV7

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

  22. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B000H9N

      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. B000GXO

        Connect the connector.

      2. Engage the 2 claws.

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


    1. B000H3H

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

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


    1. B000NFR

      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. B000HP1

      Install the hole plug.

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


    1. B000JIB

      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. B000MX5

      Install the hole plug.

  26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B000MAZ

      Engage the guide as shown in the illustration.

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

  27. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. B000ING

      Engage the guide as shown in the illustration.

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

  28. INSTALL FRONT DOOR GLASS RUN


    1. B000MWB

      Install the front door glass run.

  29. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION


    1. Clean the front door panel sub-assembly.

    2. B000HIME01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 2 guides.

    3. Install a new No. 2 front door stiffener cushion with the 2 bolts.

  30. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the power window regulator motor.


    1. B000ICI

      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

      A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  31. 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. B000ITZE02
      Text in Illustration
      *1 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 }

  32. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

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

      Note

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

    4. Disconnect the multiplex network master switch assembly.

    5. B000LNYE01

      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.

    6. B000HBB

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    7. B000LXE

      Install the grommet.

  33. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. B000MIAE01
      Text in Illustration
      *1 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.

    4. Engage the 4 clamps.

    5. Connect each connector.

  34. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)


    1. Install the outer mirror control ECU assembly with the 2 screws.

    2. Connect each connector.

  35. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY


    1. Engage the claw to temporarily install the outer rear view mirror assembly.

    2. Install the outer rear view mirror assembly with the 3 bolts.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

    3. Connect the connector.

  36. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


    1. Engage the 2 claws to the vehicle body to temporarily install the front No. 1 speaker assembly.

    2. B000HKVE01
      Text in Illustration
      *A LH Side
      *B RH Side

      Install the front No. 1 speaker assembly with the 4 screws.

      Note

      Do not touch the speaker cone.

      Tech Tips

      Install the screws in the order shown in the illustration.

    3. Connect the connector.

  37. INSTALL SEAT MEMORY SWITCH (w/ Memory)


    1. B000LAI

      Engage the 4 claws to install the seat memory switch to the front door trim board sub-assembly LH.

  38. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B000MP8

      Install the front door inner glass weatherstrip.

  39. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY


    1. Engage the claw and 3 clamps, and install the front door inside handle illumination light assembly.

  40. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B000J2V

      Engage the 2 claws and guide, and install the front door inside handle sub-assembly to the front door trim board sub-assembly.

  41. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B000KO6E01
      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.

    2. w/o Memory:


      1. Connect the connector.

    3. w/ Memory:


      1. Connect the 2 connectors.

    4. B000KHDE01
      Text in Illustration
      *1 Reference Boss

      Engage the front door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

    5. B000NJZ

      Engage the 10 clips and install the front door trim board sub-assembly.

    6. Install the 3 screws.

    7. If protective tape has been applied, remove it.

  42. INSTALL COURTESY LIGHT ASSEMBLY


    1. Connect the connector.

    2. B000I67E01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Engage the claw to install the courtesy light assembly.

  43. INSTALL FRONT ARMREST ASSEMBLY


    1. B000LDC

      Engage the 2 guides, 3 clips and 7 claws, and install the front armrest assembly.

  44. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)


    1. Connect each connector.

    2. B000IAE

      Engage the 4 guides, 2 clips and 5 claws, and install the multiplex network master switch assembly with front door armrest base panel.

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


    1. Connect the connector.

    2. B000MFS

      Engage the 4 guides, 2 clips and 5 claws, and install the power window regulator switch assembly with front door armrest base panel.

  46. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B000LAY

      Engage the 3 clips to install the front door lower frame bracket garnish.

  47. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B000HXN

      Engage the 3 claws to install the front door inside handle bezel plug.

  48. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  49. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  50. INSPECT POWER WINDOW OPERATION

    Click here