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FRONT DOOR REASSEMBLY

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CAUTION / NOTICE / HINT

Tip:

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

  • The following procedure is for the LH side.

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PROCEDURE


  1. Click here

    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. Click here

    INSTALL FRONT DOOR BELT MOULDING

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  3. Click here

    INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

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  4. Click here

    INSTALL FRONT DOOR PANEL CUSHION


    1. B0066JK

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

  5. Click here

    INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. B00653B

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

  6. Click here

    INSTALL FRONT DOOR WEATHERSTRIP


    1. B0066XG

      Engage the 20 clips to install the front door weatherstrip.

  7. Click here

    INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. Clean the bolt hole on the vehicle body.

    3. Clean the threads of the bolt.

    4. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. B0067DEC02
      B0067U9 Nut
      B00679M Bolt

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

      Nut
      8.0 N*m 82 kgf*cm 71 in.*lbf
      Bolt
      27 N*m 275 kgf*cm 20 ft.*lbf
  8. Click here

    INSTALL FRONT DOOR VENT SEAL


    1. B0066ZL

      Install the front door vent seal.

  9. Click here

    INSTALL FRONT DOOR DIVISION BAR SEAL


    1. B00670I

      Engage the claw.

    2. Engage the 2 clips to install the front door division bar seal.

  10. Click here

    INSTALL DOOR GLASS FEMALE STABILIZER


    1. B0067BC

      Engage the 2 guides.

    2. Install the door glass female stabilizer with the bolt.

      11.5 N*m 117 kgf*cm 8 ft.*lbf
  11. Click here

    INSTALL FRONT DOOR LOCK OPEN ROD


    1. B0066V3N01

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

  12. Click here

    INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. B0066YTC01
      *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.

      4.0 N*m 41 kgf*cm 35 in.*lbf
    4. B0066MQ

      Engage the 3 clamps.

  13. Click here

    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 with a new one.

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

    • Reusing a 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. B0065U9

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

    3. B0067ABC01
      *1 Front Door Lock Open Rod

      Connect the front door lock open rod to the front door lock with motor assembly.

      Tip:

      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.

      5.5 N*m 56 kgf*cm 49 in.*lbf

    5. Connect the connector.

  14. Click here

    INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B0067YE

      Engage the 3 guides as shown in the illustration.

    2. B0065YD

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

  15. Click here

    INSTALL FRONT DOOR OUTSIDE HANDLE PAD


    1. B0065XD

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

  16. Click here

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


    1. B0066JH

      Engage the 2 guides and claw.

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

      4.0 N*m 41 kgf*cm 35 in.*lbf
    3. B00667H

      Install the hole plug.

  17. Click here

    INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)


    1. B00685Y

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

      4.0 N*m 41 kgf*cm 35 in.*lbf
    2. B006530

      Install the hole plug.

  18. Click here

    INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B0065DZ

      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. B0065UM

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

    4. Connect the connector.

    5. B0067XH

      Engage the 2 claws.

  19. Click here

    INSTALL FRONT DOOR GLASS RUN


    1. B0066B9

      Engage the guide to install the front door glass run.

  20. Click here

    INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. B00677SN01

      Using a 4 mm hexagon wrench, adjust the 2 stud bolts at the bottom of the front door window regulator assembly as shown in the illustration.

      Table 1. Standard Clearance
      A 21.1 to 22.1 mm (0.831 to 0.870 in.)

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

    3. B0067M4

      Temporarily install the front door window regulator assembly with the 7 nuts.

    4. B0066A7

      Install the 2 window regulator shims.

    5. B0067M4N01

      Tighten the 7 nuts to install the front door window regulator assembly.

      Nut (A)
      5.5 N*m 56 kgf*cm 49 in.*lbf
      Nut (B)
      13 N*m 133 kgf*cm 10 ft.*lbf
    6. B0067U0

      Connect the connector.

  21. Click here

    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 window regulator assembly so that the door glass stud bolts can be seen.

    3. for Front Passenger Side:


      1. Connect the power window regulator switch assembly and move the front door window regulator assembly so that the door glass stud 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. B00661VN01

      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. B0065B8

      Install the front door glass sub-assembly with the 3 nuts.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  22. Click here

    INSTALL FRONT DOOR UPPER WINDOW STOP


    1. for Front Side:


      1. B0065IA

        Install the front door upper window stop with the bolt.

        11.5 N*m 117 kgf*cm 8 ft.*lbf

    2. for Rear Side:


      1. B006725

        Install the front door upper window stop with the bolt.

        11.5 N*m 117 kgf*cm 8 ft.*lbf
  23. Click here

    INSPECT 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 fully close the front door glass sub-assembly.

    3. for Front Passenger Side:


      1. Connect the power window regulator switch assembly and fully close the front door glass sub-assembly.

    4. B0066V4N01

      Check that the clearance measurements of areas a through m are within each standard range.

      Table 2. Standard Clearance
      Area Measurement Area Measurement
      a 15.0 mm (0.591 in.) b 5.6 to 9.6 mm (0.220 to 0.378 in.)
      c 9.1 to 13.1 mm (0.358 to 0.516 in.) d 15.0 mm (0.591 in.)
      e 5.7 to 9.7 mm (0.224 to 0.382 in.) f 9.1 to 13.1 mm (0.358 to 0.516 in.)
      g 15.0 mm (0.591 in.) h 5.7 to 9.7 mm (0.224 to 0.382 in.)
      i 9.1 to 13.1 mm (0.358 to 0.516 in.) j 12.0 mm (0.472 in.)
      k 0 mm (0 in.) l 12.0 mm (0.472 in.)
      m 0 mm (0 in.) - -
      Note:

      Be careful not to cut the weatherstrip during door glass adjustment.

  24. Click here

    ADJUST FRONT DOOR GLASS SUB-ASSEMBLY


    1. B00685E

      Adjust the fit of the top part of the front door glass sub-assembly inward and outward.


      1. Loosen the 2 nuts at the bottom of the front door window regulator assembly.

      2. Using a 4 mm hexagon wrench, turn the 2 stud bolts to adjust the fit of the top part of the front door glass sub-assembly inward and outward.

        Tip:

        When the stud bolt are turned counterclockwise, the top part of the front door glass sub-assembly moves toward the inside of the vehicle. When the stud bolt are turned clockwise, the top part of the front door glass sub-assembly moves toward the outside of the vehicle.

      3. Tighten the 2 nuts after adjustment.

        13 N*m 133 kgf*cm 10 ft.*lbf
    2. B0066OX

      Adjust the fit of the bottom part of the front door glass sub-assembly inward and outward.


      1. Loosen the 2 nuts at the top of the front door window regulator assembly.

      2. Change the number of installed window regulator shims to adjust the fit of the bottom part of the front door glass sub-assembly inward and outward.

        Tip:

        When more shims are used, the bottom part of the front door glass sub-assembly moves toward the outside of the vehicle. When less shims are used, the bottom part of the front door glass sub-assembly moves toward the inside of the vehicle.

      3. Tighten the 2 nuts after adjustment.

        5.5 N*m 56 kgf*cm 49 in.*lbf
    3. B0066WP

      Adjust the front door glass sub-assembly fully closed position horizontally and vertically.


      1. Loosen the 2 front door upper window stop bolts and temporarily move the front door upper window stops to the top of their adjustment range and then temporarily tighten the bolts.

      2. Loosen the 3 front door glass sub-assembly nuts.

      3. Stop the front door glass sub-assembly approximately 3 mm (0.118 in.) below the fully closed position.

      4. While holding the front door glass sub-assembly, move it vertically and horizontally to adjust its position.

      5. Tighten the 3 nuts after adjustment.

        5.5 N*m 56 kgf*cm 49 in.*lbf

      6. Move the front door glass sub-assembly to the fully closed position.

      7. Loosen the 2 front door upper window stop bolts.

      8. While lightly pushing each front door upper window stop against the stopper on the front door glass sub-assembly, tighten each bolt.

        15 N*m 153 kgf*cm 133 in.*lbf

    4. for Driver Side:


      1. Disconnect the multiplex network master switch assembly.

    5. for Front Passenger Side:


      1. Disconnect the power window regulator switch assembly.

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

  25. Click here

    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. B0065IVC01
      *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.

  26. Click here

    INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

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  27. Click here

    INSTALL FRONT DOOR TRIM BRACKET


    1. B00680M

      Install the front door trim bracket with the 2 screws.

  28. Click here

    INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B0067KC

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

  29. Click here

    INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

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  30. Click here

    INSTALL OUTER MIRROR PROTECTOR

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  31. Click here

    INSTALL OUTER MIRROR INSTALL HOLE COVER

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  32. Click here

    INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY

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  33. Click here

    INSTALL DOOR SIDE AIRBAG SENSOR

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  34. Click here

    INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B00678J

      Engage the 9 claws to install the front door inner glass weatherstrip as shown in the illustration.

  35. Click here

    INSTALL SEAT MEMORY SWITCH (w/ Memory)

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  36. Click here

    INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B0067QT

      Install the front door inside handle sub-assembly with the 7 screws.

  37. Click here

    INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY

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  38. Click here

    INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B0066W5C01
      *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. Connect each connector.

    3. B0065UT

      Engage the 9 clips to install the front door trim board sub-assembly as shown in the illustration.

    4. B00678SN01

      Install the 4 screws.

      Screw (A)
      3.5 N*m 36 kgf*cm 31 in.*lbf
  39. Click here

    INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. B0067H0

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

  40. Click here

    INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  41. Click here

    INSTALL DOOR TRIM COVER


    1. B0066QY

      Install the door trim cover.

  42. Click here

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


    1. Connect the connector.

    2. B0065NSC04
      B00667M Push Area

      Engage the 2 clips, 7 claws and 5 guides to install the multiplex network master switch assembly with front door armrest base panel.

    3. Press the push area.

      Tip:

      Check that the front door armrest base panel are attached to the front door trim board sub-assembly correctly.

  43. Click here

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


    1. Connect the connector.

    2. B0065OEC04
      B00667M Push Area

      Engage the 2 clips, 7 claws and 5 guides to install the power window regulator switch assembly with front door armrest base panel.

    3. Press the push area.

      Tip:

      Check that the front door armrest base panel are attached to the front door trim board sub-assembly correctly.

  44. Click here

    INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B0065R4

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

  45. Click here

    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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  46. Click here

    INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  47. Click here

    INSPECT POWER WINDOW OPERATION

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  48. Click here

    INSPECT SRS WARNING LIGHT

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