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. REPAIR INSTRUCTION

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  2. INSTALL NO. 1 BLACK OUT TAPE LH

    Click here

  3. INSTALL NO. 2 BLACK OUT TAPE LH

    Click here

  4. INSTALL NO. 3 BLACK OUT TAPE LH

    Click here

  5. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH

    Click here

  6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Click here

  7. INSTALL HOLE PLUG


    1. Install the hole plug.

  8. INSTALL FRONT DOOR PANEL CUSHION


    1. Install the 2 front door panel cushions.

  9. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

    Click here

  10. INSTALL FRONT DOOR UPPER OUTSIDE MOULDING PAD

    Click here

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

    Click here

  12. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. Attach the 24 clips to install the front door weatherstrip LH.

  13. INSTALL UPPER DOOR FRAME GARNISH LH


    1. Install a new upper door frame garnish LH.

  14. 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:


      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 nuts.

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

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

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  15. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

  16. INSTALL DOOR OUTSIDE HANDLE BUSH


    1. Install the door outside handle bush.

  17. 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. B002IRBC01
      *1 Snap

      Rotate the snap as shown in the illustration to attach the snap to the front door lock open rod LH.

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


    1. B002IH3

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

    2. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly LH with the screw as shown in the illustration.

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

    3. Attach the clamp.

  19. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


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

  20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. Attach the 4 claws to install the front door rear outside handle pad.

  21. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY LH (for Driver Side)


    1. Using a mechanical key, temporarily install the front door lock cylinder assembly LH as shown in the illustration.

      B002I3KC01
      *a 30° - -
    2. B002I49

      Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly LH with the screw.

    3. Install the hole plug.

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


    1. B002HXG

      Using a T30 "TORX" socket wrench, install the front door outside handle cover RH with the screw.

    2. Install the hole plug.

  23. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B002H7J

      Temporarily install the front door outside handle assembly LH in the direction of the arrow shown in the illustration.

    2. B002J7K

      Attach the 2 claws to install the holder to the front door outside handle assembly LH.

    3. B002IRP

      Attach the 3 claws to connect the connector and connector cover.

  24. 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.

  25. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. B002I02C02
      B002JLO Double-sided tape

      Clean vehicle installation surface.


      1. Remove any remaining double-sided tape from the vehicle installation surface.

      2. Clean the front door panel sub-assembly RH installation surface with non-residue solvent.

    2. Remove the peeling paper on a new front door No. 1 stiffener cushion while making sure not to touch the adhesional surface.

    3. Install the front door No. 1 stiffener cushion with the 2 bolts.

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

    4. Press the front door No. 1 stiffener cushion against the door panel.

  26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. B002J1VC02
      *1 Temporarily Bolt

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

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

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

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

      Note

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

  27. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP LH


    1. Install the front door fix window weatherstrip LH.

  28. INSTALL FRONT DOOR FIX WINDOW GLASS LH


    1. B002I0Z

      Install the front door fix window glass LH in the direction indicated by the arrow in the illustration.

  29. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH


    1. B002HBTC05
      B002HVY Bolt
      B002I10 Screw

      Lift up the weatherstrip, and then install the front door front lower frame sub-assembly LH with the screw.

    2. Install the 3 bolts.

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

  30. 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 auxiliary battery negative (-) terminal.

    3. Move the front door window regulator so that the front door glass bolts can be seen.

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

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the auxiliary battery negative (-) terminal to disable the SRS system.

      Note

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

      Click here

    5. B002IE4N01

      Insert the front door glass sub-assembly LH in the door panel sub-assembly LH in the order shown in the illustration.

      Note

      Be careful not to damage the front door glass sub-assembly LH.

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

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

    7. Install the hole plug.

  31. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run LH.

  32. INSTALL DOOR SIDE AIR BAG SENSOR LH

    Click here

  33. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. B002ILEC01
      *a Reference Point
      B002HVY Connector
      B002I10 Bolt

      Apply new butyl tape to the front door panel.

    2. Pass each cable and connector through a new front door service hole cover LH.

    3. Attach the front door service hole cover LH by aligning it with the reference points on the front door panel.

      Tech Tips

      Securely install the front door service hole cover LH by attaching it without any wrinkles or air bubbles.

    4. Attach the 3 clamps.

    5. Install the ground wire with the bolt.

    6. Connect the 3 connectors.

  34. INSTALL FRONT DOOR NO. 2 SERVICE HOLE COVER (w/o Front Speaker)


    1. Install the front door No. 2 service hole cover with the 3 bolts.

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

    Click here

  36. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  37. INSTALL OUTER MIRROR INSTALL HOLE COVER LH

    Click here

  38. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY

    Click here

  39. INSTALL FRONT DOOR ARMREST SET BRACKET LH


    1. Install the 2 screws to the front door armrest set bracket LH.

  40. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. Install the front door inner glass weatherstrip LH.

  41. INSTALL FRONT SEAT SLIDE SWITCH BEZEL (for Driver Side with Memory)

    Click here

  42. INSTALL SEAT MEMORY SWITCH (for Driver Side with Memory)

    Click here

  43. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


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

  44. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B002J8J

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

    2. Attach the 2 clamps.

    3. for Driver Side with Memory:


      1. Disconnect the connector.

    4. B002H8Z

      Attach the 8 clips to install the front door trim board sub-assembly LH.

    5. B002HGNC02
      B002HVY Screw A
      B002I10 Screw B
      B002H26 Screw C

      Install the screw labeled A.

    6. Install the screw labeled B.

    7. Install the screw labeled C.

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


    1. Connect the 2 connectors.

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

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


    1. Connect the 2 connectors.

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

  47. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


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

  48. INSTALL FRONT DOOR TRIM COVER LH


    1. Install the front door trim cover LH.

  49. 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


    1. w/o Spare Tire:

      Detach the 2 claws and remove the battery service cover.

    2. Tighten the nut and connect the cable from to auxiliary battery negative (-) terminal.

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

  50. INSTALL DECK FLOOR BOX LH (w/ Spare Tire)

    Click here

  51. INSTALL REAR DECK FLOOR BOX (w/ Spare Tire)

    Click here

  52. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  53. PERFORM DIAGNOSTIC SYSTEM CHECK

    Click here

  54. CHECK SRS WARNING LIGHT

    Click here

  55. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  56. CHECK POWER WINDOW CONTROL SYSTEM

    Click here

  57. INSPECT FRONT POWER SEAT CONTROL SYSTEM (for Driver Side with Memory)

    Click here

  58. CHECK POWER DOOR LOCK CONTROL SYSTEM

    Click here