FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The following procedure 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.

    Click here

  2. INSTALL FRONT DOOR UPPER OUTSIDE MOULDING PAD

    Click here

  3. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  4. REPAIR INSTRUCTION

    Click here

  5. INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE

    Click here

  6. INSTALL FRONT DOOR UPPER INNER BLACK OUT TAPE

    Click here

  7. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

    Click here

  8. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  9. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  10. INSTALL FRONT DOOR VENT SEAL


    1. A002BPIN01

      Install the front door vent seal.

  11. INSTALL FRONT DOOR PANEL PROTECTOR


    1. A0029VAN01

      Install the front door panel protector.

      Tech Tips

      Press the area (a) shown in the illustration to confirm that the front door panel protector is securely installed to the door.

  12. INSTALL FRONT DOOR PANEL CUSHION


    1. A0027WE

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

  13. INSTALL DOOR FRAME GARNISH


    1. A00272V

      Engage the 3 claws to install the door frame garnish.

  14. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


    1. Clean the front door panel.

    2. A00299BC01
      B004057 Double-sided Tape

      Engage the 2 guides.

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

  15. INSTALL FRONT DOOR WEATHERSTRIP


    1. A002788

      Engage the 20 clips to install the front door weatherstrip.

  16. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole on the vehicle body.

    3. Clean the bolt threads of the bolt.

    4. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A00272CC02
      B003ZIE Bolt
      B003Z8F Nut

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

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

  17. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A002AYYN01

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

  18. 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. A0029ZXC01
      *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:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    4. w/ Smart Entry and Start System:


      1. A002ATL

        Engage the 3 clamps.

  19. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A002ADV

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

  20. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A0028RP

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

    2. A002CKD

      Engage the 2 claws as shown in the illustration.

  21. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

    Note


    • When reusing a removed front door lock with motor assembly, replace the door lock wiring harness seal with a new one.

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

    • Reusing a door lock wiring harness seal or using a damaged door lock wiring 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. A00287G

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

    3. A002BFRC01
      *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:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    5. Connect the connector.

  22. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A002A08

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

  23. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A002BMX

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

  24. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A002BPH

      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. w/ Smart Entry and Start System:


      1. A002A5Q

        Connect the connector.

      2. Engage the 2 claws.

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


    1. A00283E

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

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


    1. A0027FT

      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. A0028LD

      Install the hole plug.

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


    1. A0029EC

      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. A002A28

      Install the hole plug.

  28. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A002792

      Engage the guide.

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

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

  29. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. A002ADD

      Engage the guide.

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

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }
    3. A00296P

      Connect the wire harness with the 2 bolts.

      Torque:
      7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

  30. INSTALL FRONT DOOR GLASS RUN


    1. A002A30

      Install the front door glass run.

  31. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

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


    1. A002BES

      Using a T25 "TORX" socket wrench, install the power window regulator motor assembly with the 3 screws.

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

      Tech Tips

      When replacing a power window regulator motor assembly, a new power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  32. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. Apply MP grease to the sliding parts of the front door window regulator assembly.

    2. Temporary install the temporary bolt to the front door window regulator assembly.

    3. A0027BTC01
      *a Temporary Bolt

      Temporarily install the front door window regulator assembly with the 5 bolts.

    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.

  33. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

      2. Disconnect the power window regulator master switch assembly.

    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.

      2. Disconnect the power window regulator switch assembly.

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

    5. Disconnect the multiplex network master switch assembly.

    6. A002C75N01

      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.

    7. A002A6M

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    8. A002CP3

      Install the grommet.

  34. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. A0027QQC01
      *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. Install the new 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.

  35. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  36. INSTALL OUTER REAR VIEW MIRROR WITH COVER

    Click here

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

    Click here

  38. INSTALL SEAT MEMORY SWITCH (w/ Memory)

    Click here

  39. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A0027M9

      Engage the 7 claws to install the front door inner glass weatherstrip as shown in the illustration.

  40. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A0029CD

      Engage the guide and 2 claws to 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. A002ANAC01
      *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/ Memory:


      1. Connect the connector.

    3. w/ Illumination:


      1. Connect the connector.

    4. A0028CJ

      Engage the 10 clips to install the front door trim board sub-assembly as shown in the illustration.

    5. A00294H

      Install the 3 screws.

    6. A0028MS

      Engage the claw to close the cover.

  42. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

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


    1. Connect each connector.

    2. A002899

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

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


    1. Connect each connector.

    2. A002BUV

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

  45. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A002BIG

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

  46. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. A0028TW

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

  47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  48. INITIALIZE POWER WINDOW CONTROL SYSTEM


    • for Models with Jam Protection Function on 4 Windows:

      Click here


    • for Models with Jam Protection Function on Front Door Windows:

      Click here

  49. INSPECT POWER WINDOW OPERATION


    • for Models with Jam Protection Function on 4 Windows:

      Click here


    • for Models with Jam Protection Function on Front Door Windows:

      Click here

  50. INSPECT SRS WARNING LIGHT

    Click here