FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure described below is for the LH side.

PROCEDURE


  1. 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.

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  2. REPAIR INSTRUCTION

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  3. INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE

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  4. INSTALL FRONT DOOR INNER UPPER BLACK OUT TAPE

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  5. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

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  6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

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  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

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  8. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

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  9. INSTALL FRONT DOOR VENT SEAL


    1. A01MWKC

      Install the front door vent seal.

  10. INSTALL FRONT DOOR PANEL CUSHION


    1. B003U9A

      Engage the claw to install a new front door panel cushion.

  11. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. B003U1J

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

  12. INSTALL DOOR FRAME GARNISH


    1. B003WU6

      Engage the 3 claws to install the door frame garnish.

  13. INSTALL FRONT DOOR WEATHERSTRIP


    1. Clean the front door panel sub-assembly.

    2. Remove the release paper from a new front door weatherstrip.

      Tech Tips

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

    3. B003SUYC02
      B003V9P Double-sided Tape

      Engage the 21 clips and install the front door weatherstrip.

  14. 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. B003VP0C02
      B003WAF Nut
      B003U82 Bolt

      Install the front door check assembly with the 2 nuts and bolt.

      Torque:
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  15. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B003TG1N01

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

  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. B003TBH

      Engage the 3 clamps.

    3. Set the front door outside handle frame sub-assembly to the front door panel.

    4. B003X5EC01
      *A Outside
      *B Inside

      Engage the claw.

    5. 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 }

  17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. w/o Double Locking System:


      1. B003U45

        Install the front door inside locking cable assembly as shown in the illustration.

    2. w/ Double Locking System:


      1. B003T39

        Install the front door inside locking cable assembly as shown in the illustration.

      2. B003WWB

        Engage the 3 claws as shown in the illustration.

  18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. B003W1V

      w/o Double Locking System:


      1. Install the front door lock remote control cable assembly as shown in the illustration.

      2. B003W7M

        Engage the 2 claws as shown in the illustration.

    2. w/ Double Locking System:


      1. B003V6Q

        Install the front door lock remote control cable assembly as shown in the illustration.

  19. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

    Note


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

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

    • Reusing the door lock wire harness seal or using a damaged door lock wire 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. B003VN8

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

    3. B003UKOC01
      *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:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    5. Connect the connector.

  20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B003VVK

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

  21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B003TB5

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

  22. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B003VOD

      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. B003UUS

      Move the lever as shown in the illustration to lock the front door outside handle assembly.

    4. B003V0P

      Connect the connector.

    5. Engage the 2 claws.

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


    1. B003WHF

      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. B003TAE

      Install the hole plug.

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


    1. B003V87

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

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


    1. B003WC8

      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. B003X59

      Install the hole plug.

  26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B003SXQ

      Engage the guide as shown in the illustration.

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

  27. INSTALL FRONT DOOR GLASS RUN


    1. B003W8A

      Install the front door glass run.

  28. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


    1. Clean the front door panel sub-assembly.

    2. Remove the release paper from a new front door No. 2 stiffener cushion.

      Tech Tips

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

    3. B003VVQC02
      B003V9P Double-sided Tape

      Engage the guide.

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

  29. 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. B003V2Q

      Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws to front door window regulator sub-assembly.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      When replacing a 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.

  30. 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. B003UFCC01
      *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:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    5. Connect the connector.

  31. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. for Driver Side:


      1. 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. 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 multiplex network master switch assembly.

    6. for Front Passenger Side:


      1. Disconnect the power window regulator switch assembly.

    7. B003VSYN01

      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. B003SXE

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

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

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  33. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. 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. B003W1SC01
      *a Reference Point

      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.

  34. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

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  35. INSTALL OUTER MIRROR PROTECTOR

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  36. INSTALL OUTER MIRROR INSTALL HOLE COVER

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  37. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Automatic Retractable Mirror)

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  38. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B003UCQ

      Engage the 2 clips to install the front door lower frame bracket garnish.

  39. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B003T1D

      Install the front door inner glass weatherstrip.

  40. INSTALL SEAT MEMORY SWITCH (w/ Memory)

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  41. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY

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  42. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B003UPL

      Engage the 3 guides.

    2. Install the front door inside handle sub-assembly with the 6 screws.

  43. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. Connect each connector.

    2. B003WOTC01
      *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.

    3. B003U83C01
      *a Reference Boss

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

    4. B003WGI

      Engage the 9 clips and install the front door trim board sub-assembly.

      Tech Tips

      If protective tape has been applied, remove it.

    5. Install the 3 screws.

  44. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. B003T9B

      Install the front door No. 1 stiffener cushion with the screw.

  45. INSTALL COURTESY LIGHT ASSEMBLY

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  46. INSTALL FRONT DOOR ARMREST COVER


    1. B003WBE

      Engage the 2 guides.

    2. Engage the 2 claws, and install the front door armrest cover.

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


    1. Connect the connector.

    2. B003SYL

      Engage the 2 clips, 7 claws and 6 guides, and install the multiplex network master switch assembly with front door armrest base panel.

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


    1. Connect the connector.

    2. B003UWQ

      Engage the 2 clips, 7 claws and 6 guides, and install the power window regulator switch assembly with front door armrest base panel.

  49. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B003U3C

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

  50. 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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  51. INITIALIZE POWER WINDOW CONTROL SYSTEM

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  52. INSPECT POWER WINDOW OPERATION

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