FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure listed below is for the RH side.

  • Use the same procedure for RHD and LHD vehicles.

  • The procedure listed below are for RHD vehicles.

  • A bolt without a torque specification is shown in the standard bolt chart.

    Click here

PROCEDURE


  1. REPAIR INSTRUCTION

    Click here

  2. INSTALL NO. 1 BLACK OUT TAPE RH

    Tech Tips

    The procedure described below is for the LH side.

    Click here

  3. INSTALL FRONT DOOR WEATHERSTRIP RH


    1. B003K8X

      Attach the clip to install the front door weatherstrip RH.

  4. INSTALL FRONT DOOR CHECK ASSEMBLY RH


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

    2. When reusing a bolt:


      1. Clean the threads of the bolt (B) with non-residue solvent.

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

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. B003L32C02
      B003R2S Bolt (A)
      B003LF2 Bolt (B)

      Install the front door check assembly RH with the 2 bolts (A) and bolt (B).

      Torque:
      Bolt (A)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt (B)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  5. INSTALL FRONT DOOR DUST PROOF SEAL


    1. B003L7N

      Attach the claw to install 3 new front door dust proof seals.

  6. INSTALL FRONT DOOR PANEL CUSHION


    1. B003JKQ

      Attach the claw to install 2 new front door panel cushions.

  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY RH

    Tech Tips

    The procedure described below is for the LH side.

    Click here

  8. INSTALL FRONT DOOR LOCK OPEN ROD RH


    1. B003L9FC01
      B003OFB Install in this Direction

      Attach the snap to install the front door lock open rod RH to the front door outside handle frame sub-assembly RH as shown in the illustration.

  9. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY RH


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

    2. B003OLKC02
      *a Clamp
      *b Guide

      w/ Smart Entry and Start System:


      1. Attach the guide and clamp to connect the wire harness.

    3. B003ODQC01
      *a Grommet
      *b Guide
      B003OFB Install in this Direction

      Attach the grommet and guide to install the front door outside handle frame sub-assembly RH as shown in the illustration.

    4. Using a T30 "TORX" socket wrench, install the screw.

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

  10. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B003LARC01
      B003OFB Install in this Direction

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

  11. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B003LF0C01
      B003OFB Install in this Direction

      Attach the claw to install the front door front outside handle pad.

  12. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY RH


    1. B003QHGC01
      B003OFB Install in this Direction

      Install the front door outside handle assembly RH as shown in the illustration.

    2. w/ Smart Entry and Start System:


      1. B003OQN

        Connect the connector.

      2. B003R0AC01
        B003OFB Install in this Direction

        Attach the claw to close the connector cover as shown in the illustration.

  13. INSTALL DOOR LOCK WIRING HARNESS SEAL

    Click here

  14. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY RH

    Click here

  15. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY RH

    Click here

  16. INSTALL FRONT DOOR LOCK COVER SUB-ASSEMBLY RH (w/o Double Locking System)

    Click here

  17. INSTALL FRONT DOOR LOCK ASSEMBLY RH

    Click here

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


    1. B003RA5C01
      B003OFB Install in this Direction

      Attach the guide and claw to install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.

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


    1. Apply MP grease to the sliding area of the front door outside handle cover with lock cylinder assembly.

    2. B003S4EC01
      *1 Hole Plug
      B003OFB Install in this Direction

      Install the front door outside handle cover with lock cylinder assembly as shown in the illustration.

      Tech Tips

      Check that the front door lock cylinder assembly is inserted into the front door lock assembly RH.

    3. Using a T30 "TORX" socket wrench, install the screw.

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

    4. Install the hole plug.

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


    1. B003K9ZC01
      *1 Hole Plug
      B003OFB Install in this Direction

      Attach the claw to install the front door outside handle cover as shown in the illustration.

    2. Using a T30 "TORX" socket wrench, install the screw.

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

    3. Install the hole plug.

  21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY RH


    1. B003NFO

      Attach the guide to install the front door rear lower frame sub-assembly RH.

    2. Install the bolt.

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

  22. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY RH

    Click here

  23. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY RH


    1. Apply MP grease to the sliding area of the front door window regulator sub-assembly RH.

    2. B003OJXC02
      B003R2S Bolt
      B003LF2 Connector
      B003QHB Temporarily Bolt

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

    3. Install the front door window regulator sub-assembly RH with the 5 bolts and temporarily bolt.

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

    4. Connect the connector.

  24. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY RH


    1. Temporarily install the power window regulator master switch assembly.

    2. Connect the cable to the negative (-) battery terminal.

    3. Move the front door window regulator sub-assembly RH so that the front door glass sub-assembly RH bolts can be seen.

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

      CAUTION:


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

      • If the airbag deploys for any reason, it may cause a serious accident.

      B003RP6

      Note

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

      Click here

    5. Remove the power window regulator master switch assembly.

    6. B003L89C01
      B003OFB Install in this Direction (1)
      B003QYY Install in this Direction (2)

      Install the front door glass sub-assembly RH as shown in the illustration.

      Note

      Be careful not to damage the glass.

    7. B003LNH

      Install the 2 bolts.

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

  25. INSTALL FRONT DOOR GLASS RUN RH


    1. B003QT9

      Attach the guide to install a new front door glass run RH.

  26. INSTALL SCREW GROMMET

    B003RB7

    1. Attach the claw to install 2 new screw grommets.

  27. INSTALL FRONT DOOR SERVICE HOLE COVER RH


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

    2. B003PLDC01
      *a Reference Point
      B003QY9 Butyl Tape

      Pass the front door inside locking cable assembly RH and front door lock remote control cable assembly RH through a new front door service hole cover RH, and then attach the front door service hole cover RH using the reference points on the front door panel.

      Tech Tips


      • Securely install the front door service hole cover RH to prevent wrinkles and air bubbles.

      • There should be no wrinkles or folds after installing the front door service hole cover RH.

      • After installing the front door service hole cover RH, check the seal quality.

    3. Attach the clamp.

    4. Install the ground wire with the ground bolt.

  28. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY RH

    Tech Tips

    The procedure described below is for the LH side.

    Click here

  29. INSTALL DOOR SIDE AIR BAG SENSOR RH

    Click here

  30. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (w/ Front No. 2 Speaker)

    Click here

  31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  32. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP RH


    1. B003MQX

      Install a new front door inner glass weatherstrip RH to the front door trim board sub-assembly RH and fold down the claw in the directions indicated by the arrows in the illustration.

  33. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY RH


    1. B003OILC01
      B003OFB Install in this Direction

      Attach the claw to install the front door inside handle sub-assembly RH to the front door trim board sub-assembly RH.

  34. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY RH


    1. B003N2NC01
      *1 Front Door Inside Locking Cable Assembly RH
      *2 Front Door Lock Remote Control Cable Assembly RH
      B003OFB Install in this Direction

      Attach the clamp to connect the front door lock remote control cable assembly RH and front door inside locking cable assembly RH as shown in the illustration.

    2. B003PHMC01
      B003OFB Install in this Direction

      Attach the guide as shown in the illustration.

    3. B003JUW

      Attach the clip to install the front door trim board sub-assembly RH.

    4. B003KDF

      Install the 3 screws.

  35. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG RH


    1. B003NWL

      Attach the claw to install the front door inside handle bezel plug RH as shown in the illustration.

  36. INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)

    Click here

  37. INSTALL FRONT DOOR TRIM REFLECTOR RH (w/ Reflex Reflector Assembly)


    1. B003OO4C01
      *A for RH Side
      *B for LH Side
      B003KT0 Protective Tape
      B003OFB Install in this Direction (1)
      B003QYY Install in this Direction (2)

      Attach the guide and claw to install the front door trim reflector RH as shown in the illustration.

    2. Remove the protective tape.

  38. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)

    Click here

  39. INSTALL OUTER MIRROR SWITCH ASSEMBLY (for Driver Side)

    Click here

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


    1. Connect the each connector.

    2. B003PO7C01
      B003OFB Install in this Direction

      Attach the claw and clip to install the power window regulator master switch assembly with front door armrest base panel as shown in the illustration.

  41. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)

    Click here

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


    1. Connect the connector.

    2. B003R7JC01
      B003OFB Install in this Direction

      Attach the claw and clip to install the power window regulator switch assembly with front door armrest base panel as shown in the illustration.

  43. INSTALL FRONT ARMREST ASSEMBLY RH


    1. B003Q4VC01
      B003OFB Install in this Direction

      Attach the claw and clip to install the front armrest assembly RH.

  44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH RH


    1. Attach the claw and clip to install the front door lower frame bracket garnish RH.

      B003JRTC01
      *A w/ Front No. 2 Speaker *B w/o Front No. 2 Speaker

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  46. CHECK SRS WARNING LIGHT

    Click here