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 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.

    Click here

  2. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING

    Click here

  3. INSTALL COWL SIDE TRIM BOARD

    Click here

  4. INSTALL FRONT DOOR SCUFF PLATE

    Click here

  5. REPAIR INSTRUCTION (w/ Black Out Tape)

    Click here

  6. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE (w/ Black Out Tape)

    Click here

  7. INSTALL FRONT DOOR STRIPE (w/ Black Out Tape)

    Click here

  8. INSTALL FRONT DOOR REAR OUTSIDE STRIPE (w/ Black Out Tape)

    Click here

  9. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

    Click here

  10. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  11. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  12. INSTALL FRONT DOOR DUST PROOF SEAL


    1. B004QDC

      Engage the 3 claws to install 3 new front door dust proof seals.

  13. INSTALL FRONT DOOR PANEL CUSHION


    1. B004Q39

      Engage the 4 claws to install 2 new front door panel cushions.

  14. INSTALL FRONT DOOR FIX WINDOW GLASS


    1. Install the front door fix window glass to the front door fix window weatherstrip.

    2. B004PZDC01
      B004PI4 Install in this Direction

      Install the front door fix window glass with the front door fix window weatherstrip as shown in the illustration.

  15. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. B004Q4YC02
      B004PRK Bolt
      B004P9H Screw

      Install the front door front lower frame sub-assembly with the 3 bolts and screw.

      Torque:
      Bolt
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      Screw
      3.1 N*m  { 32 kgf*cm, 27 in.*lbf }

  16. INSTALL DOOR FRAME GARNISH


    1. B004PQ0

      Engage the 3 claws to install the door frame garnish.

  17. INSTALL FRONT DOOR WEATHERSTRIP


    1. B004PB9

      Engage the 21 clips and install the front door weatherstrip.

  18. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole in the vehicle body.

    3. Clean the threads of the bolt (B).

    4. Apply adhesive to the threads of the bolt (B).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. B004PT8N01

      Install the front door check assembly with the 3 bolts.

      Torque:
      Bolt (A)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      Bolt (B)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  19. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B004PWGC01
      B004PI4 Install in this Direction (1)
      B004OIV Install in this Direction (2)

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

  20. 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. B004Q25C01
      *A Outside
      *B Inside

      Engage the claw as shown in the illustration.

    3. 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 }

  21. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

    Click here

  22. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B004QEO

      Engage the 3 guides.

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

  23. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B004PY1

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

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


    1. B004QUB

      Engage the 2 guides and claw.

    2. 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 }
    3. B004QCJ

      Install the hole plug.

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


    1. B004PDJ

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. B004PO9

      Install the hole plug.

  26. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B004QYXC01
      B004PI4 Install in this Direction

      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. B004PVYC01
      B004PI4 Engage in this Direction

      Move the lever as shown in the illustration and engage the 2 claws to secure the front door outside handle assembly.

    4. B004QNK

      Engage the 3 clamps.

    5. B004Q1W

      Connect the connector.

    6. Engage the 2 claws.

  27. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B004P3ZC01
      B004PI4 Install in this Direction

      Engage the guide as shown in the illustration.

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

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  28. INSTALL FRONT DOOR GLASS RUN


    1. B004PQY

      Install the front door glass run.

  29. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


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

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

    3. B004QAOC01
      *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.

    6. B004Q66

      Engage the 2 claws to install the front door No. 2 service hole cover.

  30. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. for Driver Side:


      1. Connect the multiplex network master switch assembly.

    2. for Front Passenger Side:


      1. Connect the power window regulator switch assembly.

    3. Connect the cable to the negative (-) auxiliary battery terminal.

    4. Turn the power switch on (IG).

    5. Move the front door window regulator assembly so that the door glass bolt holes can be seen.

    6. Turn the power switch off.

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

    8. for Driver Side:


      1. Disconnect the multiplex network master switch assembly.

    9. for Front Passenger Side:


      1. Disconnect the power window regulator switch assembly.

    10. B004PL7C01
      B004PI4 Install in this Direction (1)
      B004OIV Install in this Direction (2)

      Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.

    11. B004Q9T

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    12. B004QP3

      Install the hole plug.

  31. INSTALL DOOR SIDE AIRBAG SENSOR

    Click here

  32. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. B004QCY

      Engage the 4 clips to install a new front door service hole cover.

    2. B004QQD

      Insert 3 new front door weatherstrip clips and turn them 45 degrees as shown in the illustration to install them.

  33. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  34. INSTALL FRONT DOOR NO. 3 SERVICE HOLE COVER


    1. B004QZD

      Install the front door No. 3 service hole cover.

  35. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  36. INSTALL FRONT DOOR PANEL PROTECTOR

    Click here

  37. INSTALL FRONT DOOR VENT SEAL


    1. B004OKCC01
      B004PI4 Install in this Direction

      Install the front door vent seal to the front door inner glass weatherstrip.

  38. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP WITH FRONT DOOR VENT SEAL


    1. B004QUGC01
      B004PI4 Install in this Direction

      Install the front door inner glass weatherstrip with front door vent seal as shown in the illustration.

    2. B004OFL

      Engage the clip.

  39. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B004PYW

      Engage the 2 claws to install the front door inside handle sub-assembly.

  40. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B004PSLC01
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
      B004PI4 Install in this Direction

      Connect the front door lock remote control cable assembly and front door inside locking cable assembly to the front door inside handle sub-assembly as shown in the illustration.

    2. B004ONH

      Engage the guide and 6 claws.

    3. Engage the 10 clips to install the front door trim board sub-assembly.

    4. B004P50

      Install the 3 screws.

  41. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

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


    1. Connect the connector.

    2. B004Q8JC01
      B004PI4 Install in this Direction

      Engage the 2 clips and 4 claws to install the multiplex network master switch assembly with front door upper armrest base panel as shown in the illustration.

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


    1. Connect the connector.

    2. B004PLGC01
      B004PI4 Install in this Direction

      Engage the 2 clips and 4 claws to install the power window regulator switch assembly with front door upper armrest base panel as shown in the illustration.

  44. INSTALL FRONT ARMREST ASSEMBLY


    1. B004QJBC01
      B004PI4 Install in this Direction

      Engage the guide as shown in the illustration.

    2. B004QE4C01
      B004PI4 Install in this Direction

      Engage the 3 clips and 7 claws to install the front armrest assembly as shown in the illustration.

  45. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B004PVH

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

  46. 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

  47. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  48. INSPECT POWER WINDOW OPERATION

    Click here

  49. INSPECT SRS WARNING LIGHT

    Click here