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 LH side.

  • Use the same procedure for RHD and LHD vehicles.

  • The procedures listed below are for LHD vehicles.

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

    Click here

PROCEDURE


  1. REPAIR INSTRUCTION (w/ Black Out Tape)

    Click here

  2. INSTALL NO. 1 BLACK OUT TAPE LH (w/ Black Out Tape)

    Click here

  3. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. B0027KL

      for Single Cab:

      Attach the clip to install the front door weatherstrip LH.

    2. B0026ZW

      for Smart Cab:


      1. Attach the clip to install a new front door weatherstrip LH.

      2. Remove the peeling paper from double-sided tape and press the double-sided tape to the front of the door panel.

    3. B0026NC

      for Double Cab:

      Attach the clip to install the front door weatherstrip LH.

  4. 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 (B).

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. B0027XDC02
      B0068HS Bolt (A)
      B006964 Bolt (B)

      Install the front door check assembly LH 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. B00275G

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

  6. INSTALL FRONT DOOR PANEL CUSHION


    1. B0025OW

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

  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

    Click here

  8. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. B0026OCC01
      B0069FO Install in this Direction

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

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


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

    2. B002778C02
      *a Clamp
      *b Guide

      Attach the guide and clamp to connect the wire harness.

    3. B002514C01
      *a Grommet
      *b Guide
      B0069FO Install in this Direction

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

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

  10. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B0025HMC01
      B0069FO 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. B00295RC01
      B0069FO Install in this Direction

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

  12. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. B0024D6C01
      B0069FO Install in this Direction

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

    2. w/ Entry and Start System:


      1. B0026SX

        Connect the connector.

      2. B0024P6C01
        B0069FO 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 LH

    Click here

  15. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

    Click here

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

    Click here

  17. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

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


    1. B0027FPC01
      B0069FO 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. B0028O4C01
      *1 Hole Plug
      B0069FO 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 LH.

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

    4. Install the hole plug.

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


    1. B00278DC01
      *1 Hole Plug
      B0069FO 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.

    3. Install the hole plug.

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


    1. B00274S

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

    2. Install the bolt.

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

  22. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (w/ Power Window)

    Click here

  23. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. Apply MP grease to the sliding area 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. w/ Power Window:


      1. Install the front door window regulator sub-assembly LH 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 }

      2. Connect the connector.

    4. w/o Power Window:

      Install the front door window regulator sub-assembly LH with the 4 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 }
      B0025HOC07
      *A w/ Power Window *B w/o Power Window
      B0068HS Bolt B006964 Connector
      B0069AV Temporarily Bolt - -

  24. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. w/ Power Window:


      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 LH so that the front door glass sub-assembly LH bolts can be seen.

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

        CAUTION:

        w/ Curtain Shield Airbag:

        • 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.

        B00693Q

        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.

    2. B0025XUC01
      B0069FO Install in this Direction (1)
      B0068NX Install in this Direction (2)

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

      Note

      Do not damage the front door glass sub-assembly LH.

    3. B0028ZY

      Install the 2 bolts.

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

  25. INSTALL FRONT DOOR GLASS RUN LH


    1. B0026C0

      for Single Cab, Smart Cab:

      Attach the guide to install the front door glass run LH.

    2. B0026C0

      for Double Cab:

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

  26. INSTALL SCREW GROMMET

    B0027E8

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

  27. INSTALL FRONT DOOR SERVICE HOLE COVER LH


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

    2. B0025Z0C01
      *a Reference Point

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

      Tech Tips


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

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

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

    3. Attach the clamp.

    4. w/ Power Mirror Control System:

      Attach the clamp.

    5. w/o Power Mirror Control System, w/ Side Turn Signal Light:

      Attach the clamp.

    6. w/ Curtain Shield Airbag:

      Install the ground wire with the ground bolt.

  28. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  29. INSTALL DOOR SIDE AIR BAG SENSOR LH (w/ Curtain Shield Airbag)

    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 LH


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

      B0028H6C03
      *A for Single Cab, Smart Cab *B for Double Cab

  33. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. B0028A9C01
      B0069FO Install in this Direction

      Attach the claw and guide to install the front door inside handle sub-assembly LH to the front door trim board sub-assembly LH.

  34. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. B0027ZRC01
      *1 Front Door Inside Locking Cable Assembly LH
      *2 Front Door Lock Remote Control Cable Assembly LH
      B0069FO Install in this Direction

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

    2. B0025X1C01
      B0069FO Install in this Direction

      Attach the guide as shown in the illustration.

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

      B0027W2C04
      *A for Single Cab, Smart Cab *B for Double Cab
    4. B0024NX

      Install the 3 screws.

  35. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


    1. B0027IM

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

  36. INSTALL FRONT DOOR TRIM REFLECTOR LH (w/ Reflex Reflector Assembly)


    1. B00265MC09
      *A for LH Side
      *B for RH Side
      B00692L Protective Tape
      B0069FO Install in this Direction (1)
      B0068NX Install in this Direction (2)

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

    2. Remove the protective tape.

  37. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side, w/ Power Window)


    1. for Models with Jam Protection Function on Driver Door Window Only:

      Click here

    2. except Models with Jam Protection Function on Driver Door Window Only:

      Click here

  38. INSTALL OUTER MIRROR SWITCH ASSEMBLY (for Driver Side, w/ Power Window)

    Click here

  39. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side, w/ Power Window)


    1. Connect each connector.

    2. B0025OKC03
      *A for Single Cab, Smart Cab
      *B for Double Cab
      B0069FO 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.

  40. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side, w/ Power Window)

    Click here

  41. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side, w/ Power Window)


    1. Connect the connector.

    2. B0024DLC01
      B0069FO 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.

  42. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)


    1. B0024WDC01
      *1 Plate
      *a Front
      *b 30°

      With the door window fully closed, install the plate and front door window regulator handle with the snap ring as shown in the illustration.

  43. INSTALL FRONT ARMREST ASSEMBLY LH


    1. B0026KWC01
      B0069FO Install in this Direction

      for Single Cab, Smart Cab:

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

    2. B0026GRC01
      B0069FO Install in this Direction

      for Double Cab:

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

  44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. Attach the guide and clip to install the front door lower frame bracket garnish LH.

      B0027TLC07
      *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 (w/ Curtain Shield Airbag)

    for Type B:

    Click here

    for Type C:

    Click here