FRONT DOOR 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 power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative(-) auxiliary 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. A00YNXOC01
      *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. A00YOS3

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

  8. INSTALL FRONT DOOR DUST PROOF SEAL


    1. A00YQ55

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

  9. INSTALL DOOR WINDOW FRAME MOULDING CLIP


    1. A00YQ1F

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

  10. INSTALL DOOR FRAME GARNISH


    1. A00YN2C

      Engage the clip to install a new door frame garnish.

  11. INSTALL FRONT DOOR WEATHERSTRIP


    1. A00YNY5

      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. A00YPSEN01

      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. A00YO6EN01

      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. A00YO6VC01
      *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 Function:


      1. A00YMNE

        Engage the 3 clamps.

  15. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A00YNPT

      Install the front door inside locking cable assembly.

    2. A00YNOJ

      Engage the 3 claws.

  16. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A00YNJM

      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. A00YOCS

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

    3. A00YNGHC01
      *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. A00YMS0

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

  19. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A00YOGA

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

  20. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A00YPLI

      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 Function:


      1. A00YPSN

        Connect the connector.

      2. Engage the 2 claws.

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


    1. A00YPDU

      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. A00YN3Y

      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. A00YP2J

      Install the hole plug.

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


    1. A00YPHB

      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. A00YP3M

      Install the hole plug.

  24. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A00YNRW

      Engage the guide.

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

  25. INSTALL FRONT DOOR GLASS RUN


    1. A00YOSG

      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. A00YO5RC01
      *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 (-) auxiliary 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 (-) auxiliary 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. A00YPN7N01

      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. A00YP50

      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. A00YNK3C01
      *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. A00YQ2OC01
      *a Reference Point

      Attach a new 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. A00YP6J

      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. A00YOZK

      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. A00YOMAC01
      *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. A00YNLK

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

    3. A00YQ36

      Install the 3 screws.

    4. A00YOFL

      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. A00YPN6

      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. A00YN0I

      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. A00YNLM

      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. A00YOF1

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

  40. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

    Click here

  41. INSTALL BATTERY BOX COVER

    Click here

  42. 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

  43. 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