FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below is for LHD vehicles.

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

  • The procedure listed below is for the LH side.

  • A bolt without a torque specification is shown in the standard bolt chart.

    Click here

PROCEDURE


  1. INSTALL FRONT DOOR PANEL CUSHION


    1. Install 2 new front door panel cushions.

  2. INSTALL FRONT DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY LH

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  3. INSTALL NO. 1 BLACK OUT TAPE LH

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  4. INSTALL DOOR WINDOW FRAME MOULDING CLIP

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  5. INSTALL FRONT DOOR WINDOW REAR FRAME MOULDING LH

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  6. INSTALL DOOR FRAME GARNISH LH


    1. Attach the clip to install a new door frame garnish LH.

  7. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. Attach the 18 clips to install the front door weatherstrip LH.

    2. Attach the 2 clips.

  8. INSTALL FRONT DOOR CHECK ASSEMBLY LH


    1. Apply MP grease to the sliding area of the front door check assembly LH.

    2. When reusing a bolt labeled A:


      1. Clean the threads of the bolt with non-residue solvent.

      2. Apply adhesive to the threads of the bolt.

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

    3. Install the front door check assembly to the door panel with the 2 bolts labeled B.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    4. A01V9DHC02
      *1 Bolt A
      *2 Bolt B

      Install the front door check assembly to the body panel with the bolt labeled A.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  9. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. Install the front door lock open rod LH to the front door outside handle frame sub-assembly LH.

    2. A01V9JKC01
      *1 Snap

      Rotate the snap in the direction indicated by the arrow shown in the illustration to attach the snap to the front door lock open rod LH.

  10. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding area of the front door outside handle frame sub-assembly LH.

    2. A01V8GZC01
      *A Inside
      *B Outside

      Using a T30 "TORX" socket wrench, attach the claw to install the front door outside handle frame sub-assembly LH with the screw.

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

    3. w/ Entry and Start System:

      Attach the 3 clamps.

  11. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. Attach the 3 claws to install the front door front outside handle pad.

  12. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


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

  13. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. Apply MP grease to the sliding area of the front door outside handle assembly LH.

    2. A01VAOE

      Install the front door outside handle assembly LH by moving it in the direction indicated by the arrow shown in the illustration.

    3. w/ Entry and Start System:


      1. Attach the claw of the connector to connect the connector.

      2. Attach the 2 claws of the connector cover to connect the connector cover.

  14. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the front door inside locking cable assembly LH.

    2. Attach the 3 claws to close the cover.

  15. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the front door lock remote control cable assembly LH.

  16. INSTALL FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH

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  17. INSTALL DOOR LOCK CYLINDER LH


    1. Attach the 2 claws to install the door lock cylinder LH to the front door outside handle cover LH.

  18. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH


    1. Using a T30 "TORX" socket wrench, install the front door outside handle cover LH together with the front door lock cylinder with the screw.

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

    2. Install the hole plug.

  19. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

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  20. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

    Tech Tips

    When installing the front door No. 2 stiffener cushion, heat the front door panel using a heat light.

    Standard
    Item Temperature
    Front Door Panel 40 to 60°C (104 to 140°F)

    Note

    Do not heat the front door panel excessively.


    1. Clean the front door panel surface.


      1. Using a heat light, heat the front door panel surface.

      2. Remove the double-sided tape from the front door panel.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new front door No. 2 stiffener cushion.


      1. Using a heat light, heat the front door panel.

      2. Remove the peeling paper from the face of the front door No. 2 stiffener cushion.

        Tech Tips

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

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

        Tech Tips

        Press the front door No. 2 stiffener cushion firmly to install it.

        Torque:
        6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH


    1. Attach the guide to install the front door rear lower frame sub-assembly LH with the bolt.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }

  22. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

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  23. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding and rotating areas of the front door window regulator sub-assembly LH.

    2. Temporarily install the temporary bolt to the front door window regulator sub-assembly LH.

    3. A01VB4YC01
      *1 Temporary Bolt

      Install the front door window regulator sub-assembly LH with the 5 bolts, and then tighten the temporary bolt.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

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

      Note

      Be careful not to drop the front door window regulator as it may become damaged.

    4. Connect the connector.

  24. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run LH.

  25. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. Temporarily install the power window regulator master switch assembly with front door armrest base panel.

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

    3. Operate the front door window regulator so that the front door glass can be installed.

    4. Disconnect the negative (-) battery terminal.

      Note

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

      Click here

    5. Remove the power window regulator master switch assembly with front door armrest base panel.

    6. A01V8C9E01

      Insert the front door glass sub-assembly LH into the front door panel along the front door glass run LH as indicated by the arrows in the order shown in the illustration.

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

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

  26. INSTALL FRONT DOOR SERVICE HOLE COVER LH


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

    2. A01VA61C01
      *A w/ Side Airbag Sensor
      *a Reference Point

      Pass the front door inside locking cable assembly LH, front door lock remote control cable assembly LH and wire harness through a new front door service hole cover LH, and then attach the front door service hole cover LH using the reference points on the front door panel.

      Tech Tips


      • Securely install the front door service hole cover to prevent wrinkles and air bubbles.

      • There should be no wrinkles or folds after installing the front door service hole cover.

      • After installing the front door service hole cover, check the seal quality.

    3. Connect the connector.

    4. Attach the 3 clamps.

    5. w/ Side Airbag Sensor:

      Install the bolt to the wire harness.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  27. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (w/ Speaker)

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  28. INSTALL FRONT SPEAKER COVER (w/o Speaker)


    1. Install a nose piece to an air riveter or hand riveter.

    2. Insert the mandrel part of a new rivet into the nose piece.

    3. Insert the mandrel part of a new rivet into the nose piece.

    4. Using the riveter, install the front speaker cover with the 3 rivets as shown in the illustration.

      Tech Tips

      If the rivet cannot be cut, pull it once and cut it.

      A01V7MO

      Note


      • A01V9DCC06
        *1 Riveter
        *2 Mandrel
        *a INCORRECT
        *b CORRECT

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

      • A01V7DNC06
        *1 Riveter
        *a INCORRECT
        *b CORRECT

        Confirm that the rivets are seated properly against the front speaker cover.

      • Do not tilt the riveter when installing the rivet to the front speaker cover.

      • Do not leave any space between the rivet head and front speaker cover.

      • A01V8ZRC06
        *1 Riveter
        *a INCORRECT
        *b CORRECT

        Do not leave any space between the front speaker cover and front door panel. Firmly hold together the 2 items while installing the rivet.

  29. INSTALL DOOR SIDE AIRBAG SENSOR LH

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  30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

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  31. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. A01VB5B

      Install the front door inner glass weatherstrip LH to the front door trim board sub-assembly LH and fold down the 7 claws in the directions indicated by the arrows shown in the illustration.

  32. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the 2 claws and guide to install the front door inside handle sub-assembly LH.

  33. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect the front door lock remote control cable assembly LH and front door inside locking cable assembly LH.

    2. Engage the front door lock remote control cable assembly LH and front door inside locking cable assembly LH to the 2 clamps.

    3. Attach the 9 clips to install the front door trim board sub-assembly LH.

    4. Install the 3 screws.

  34. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


    1. Attach the 3 claws to install the front door inside handle bezel plug LH.

  35. INSTALL FRONT DOOR ASSIST GRIP COVER LH


    1. Attach the guide, 2 clips and 4 claws to install the front door assist grip cover LH.

  36. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)

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


    1. Connect the connector.

    2. Attach the 6 claws, 2 guides and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.

  38. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)

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


    1. Connect the connector.

    2. Attach the 6 claws, 2 guides and 2 clips to install the power window regulator switch assembly with front door armrest base panel.

  40. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. Attach the 2 claws, 2 clips and 2 guides to install the front door lower frame bracket garnish.

  41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  42. CHECK SRS WARNING LIGHT (w/ Side Airbag)

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  43. INITIALIZE POWER WINDOW CONTROL SYSTEM (w/ Jam Protection Function)

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  44. CHECK POWER WINDOW CONTROL SYSTEM

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  45. CHECK POWER DOOR LOCK CONTROL SYSTEM

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  46. CHECK OUTER REAR VIEW MIRROR

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