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 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.

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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 PANEL PROTECTOR


    1. A0020K0

      Install the front door panel protector.

  10. INSTALL FRONT DOOR PANEL CUSHION


    1. A00220G

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

  11. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. A002090

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

  12. INSTALL DOOR FRAME GARNISH


    1. A0022P2

      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. A0021XNC02
      B003YLR 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. A00236EC02
      B003XUN Nut
      B003YHT 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. A0022CTN01

      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. A00229G

      Engage the 3 clamps.

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

    4. A0021OPC01
      *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. A00215E

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

    2. w/ Double Locking System:


      1. A0021XB

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

      2. A00218F

        Engage the 3 claws as shown in the illustration.

  18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A00221J

      w/o Double Locking System:


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

      2. A0022Y7

        Engage the 2 claws as shown in the illustration.

    2. w/ Double Locking System:


      1. A0023BG

        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. A0022S9

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

    3. A00232CC01
      *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. A0020U1

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

  21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A00228G

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

  22. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A00222D

      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. A00217S

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

    4. A0021OO

      Connect the connector.

    5. Engage the 2 claws.

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


    1. A0021EX

      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. A00207Q

      Install the hole plug.

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


    1. A0020BA

      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. A0022JS

      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. A0021D2

      Install the hole plug.

  26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A0021AS

      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. A00208C

      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. A0022RLC02
      B003YLR 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. A002323

      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. A0021HCC01
      *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 (-) auxiliary 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 (-) auxiliary 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. A0022XON01

      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. A0021F4

      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. A002357C01
      *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 CONTROL ECU ASSEMBLY (w/ Memory)

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  37. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. A0021YR

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

  38. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A0021UD

      Install the front door inner glass weatherstrip.

  39. INSTALL SEAT MEMORY SWITCH (w/ Memory)

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  40. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY

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  41. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A002101

      Engage the 3 guides.

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

  42. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. Connect each connector.

    2. A00209AC01
      *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. A0021BGC01
      *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. A0020B7

      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.

  43. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. A0022G5

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

  44. INSTALL COURTESY LIGHT ASSEMBLY

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  45. INSTALL FRONT DOOR ARMREST COVER


    1. A00207P

      Engage the 2 guides.

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

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


    1. Connect the connector.

    2. A0021PQ

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

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


    1. Connect the connector.

    2. A0020JY

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

  48. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A002367

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

  49. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

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  50. INSTALL BATTERY SERVICE HOLE COVER LH

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  51. INITIALIZE POWER WINDOW CONTROL SYSTEM

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  52. INSPECT POWER WINDOW OPERATION

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