FRONT DOOR REASSEMBLY

Info Added 2017-10-06

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. INSTALL NO. 2 FRONT DOOR STRIPE

    Click here

  2. INSTALL FRONT DOOR OUTSIDE STRIPE

    Click here

  3. INSTALL NO. 4 FRONT DOOR STRIPE

    Click here

  4. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

    Click here

  5. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING

    Click here

  6. INSTALL COWL SIDE TRIM BOARD

    Click here

  7. INSTALL FRONT DOOR SCUFF PLATE

    Click here

  8. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  9. INSTALL HOLE CAP


    1. B0049AF

      Install the hole cap.

  10. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  11. INSTALL FRONT DOOR OUTSIDE MOULDING

    Click here

  12. INSTALL FRONT DOOR PANEL CUSHION


    1. B00496A

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

  13. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP


    1. B00498H

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

  14. INSTALL FRONT DOOR FIX WINDOW GLASS


    1. B004992C01
      B00497S Install in this Direction

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

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

    Click here

  16. INSTALL FRONT SPEAKER COVER (w/o Speaker)


    1. B00497DN01

      Engage the guide and claw to temporarily install the front speaker cover.

    2. Using an air riveter or a hand riveter, install the front speaker cover with 3 new rivets in the order shown in the illustration.

      Note


      • B0049AIC26
        *a Riveter
        *b Mandrel
        *c Incorrect

        Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

      • B00497LC09
        *a Riveter
        *b Incorrect

        Confirm that the rivets are seated properly against the moulding.

      • Do not tilt the riveter when installing the rivet to the moulding.

      • Do not leave any space between the rivet head and moulding.

      • B0049C1C10
        *a Riveter
        *b Incorrect

        Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

    3. B00495Q

      Connect the connector.

  17. INSTALL FRONT DOOR DUST PROOF SEAL


    1. B0049DL

      Install the 3 front door dust proof seals.

  18. INSTALL FRONT DOOR WEATHERSTRIP


    1. B0049CGC01
      *a Clip (A)

      Engage the clip (A) and other clip to install the front door weatherstrip.

  19. 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 (A).

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. B0049B4C01
      *a Bolt (A)
      *b Bolt (B)

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

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

  20. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B0049B9C01
      *a Snap
      B00497S Install in this Direction (1)
      B0049AC Install in this Direction (2)

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

  21. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. w/ Protector:


      1. B00496P

        Install the door outside handle protector with the 3 screws.

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

    3. w/ Entry and Start System:


      1. B00499IC02
        *a Guide
        *b Clamp

        Engage the clamps and guide.

      2. B00498RC01
        *a Grommet
        *b Guide
        B00497S Install in this Direction

        Engage the grommet and guides to install the front door outside handle frame sub-assembly as shown in the illustration.

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

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

    4. w/o Entry and Start System:


      1. B00495IC01
        *a Grommet
        *b Guide
        B00497S Install in this Direction

        Engage the grommet and guides to install the front door outside handle frame sub-assembly as shown in the illustration.

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

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

  22. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

    Click here

  23. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B0049ARC01
      B00497S Install in this Direction

      Engage the guides to install the front door rear outside handle pad as shown in the illustration.

  24. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B0049AXC01
      B00497S Install in this Direction

      Engage the guide and claws to install the front door front outside handle pad as shown in the illustration.

  25. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B0049E1C01
      B00497S Install in this Direction

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

    2. A005QCC

      w/ Entry and Start System:


      1. Connect the connector.

      2. Engage the claws.

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


    1. B00499HC01
      *1 Hole Plug
      B00497S Remove in this Direction

      Engage the claws to install the front door outside handle cover as shown in the illustration.

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

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

    3. Install the hole plug.

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


    1. B00498TC03
      B00497S Install in this Direction

      Engage the guides and claw to install the front door outside handle cover as shown in the illustration.

    2. Apply MP grease to the sliding area of the front door lock cylinder assembly.

    3. B0049B6C01
      *1 Hole Plug
      B00497S 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 with motor assembly.

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

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

    5. Install the hole plug.

  28. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B00495YC01
      B00497S Install in this Direction

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

    2. Install the bolt.

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

  29. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. B0049C2

      Temporarily install the front door front lower frame sub-assembly with the 2 bolts.

    2. Raise up the front door weatherstrip.

    3. Install the screw.

    4. Install the front door weatherstrip.

    5. Tighten the 2 bolts.

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

  30. INSTALL FRONT DOOR GLASS RUN


    1. B00496L

      Install the front door glass run.

  31. INSTALL DOOR FRAME UPPER GARNISH


    1. B0049CC

      Engage the guides to install the door frame upper garnish.

  32. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


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

    2. B00498JC02
      *a Temporary Bolt

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

    3. Temporarily install the front door window regulator assembly with the 5 bolts.

    4. Tighten the temporary bolt and 3 bolts to install the front door window regulator assembly.

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    5. Tighten the 2 bolts.

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

    6. Connect the connector.

  33. INSTALL NO. 2 FRONT DOOR SERVICE HOLE COVER


    1. B00498M

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

  34. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. for Driver Side:


      1. Connect the power window regulator master switch assembly.

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

      3. Move the front door glass sub-assembly so that the door glass bolt holes can be seen.

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

      5. Disconnect the power window regulator master switch assembly.

    2. for Front Passenger Side:


      1. Connect the power window regulator switch assembly.

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

      3. Move the front door glass sub-assembly so that the door glass bolt holes can be seen.

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

      5. Disconnect the power window regulator switch assembly.

    3. B00496RC01
      B00497S Install in this Direction (1)
      B0049AC 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.

      Note

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

    4. B00498C

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B0049AW

      Install the hole plug.

  35. INSTALL DOOR SIDE AIRBAG SENSOR (w/ Airbag Sensor)

    Click here

  36. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. A005PR4

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

    2. Insert 3 new front door weatherstrip clips and turn them 45° as shown in the illustration.

  37. INSTALL OUTER MIRROR PROTECTOR


    1. B00499PC01
      B00497S Install in this Direction

      Engage the claws to install the outer mirror protector as shown in the illustration.

    2. Install the 2 screws.

  38. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  39. INSTALL FRONT DOOR VENT SEAL


    1. B0049DM

      Install the front door vent seal.

  40. INSTALL FRONT DOOR BELT SEAL


    1. B0049BMC01
      B00497S Install in this Direction

      Install the front door belt seal to the front door glass inner weatherstrip as shown in the illustration.

  41. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP


    1. B00499DC01
      B00497S Install in this Direction

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

  42. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. B004991

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

  43. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY (w/ Illumination)

    Click here

  44. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B0049A4

      Engage the claw and guides to install the front door inside handle sub-assembly.

  45. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B004982C01
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
      B00497S Install in this Direction

      Engage the guides to connect the front door lock remote control cable assembly and front door inside locking cable assembly as shown in the illustration.

    2. w/ Illumination:


      1. Connect the connector.

    3. B004969C01
      B00497S Install in this Direction

      Engage the claws as shown in the illustration.

    4. B0049APC01
      *a Clip (A)

      Engage the clips (A), other clips and guide to install the front door trim board sub-assembly.

    5. B00496T

      Install the 3 screws.

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


    1. A005P5O

      Connect the 2 connectors.

    2. B0049A1C01
      B00497S Install in this Direction

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

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


    1. A005OEB

      Connect the connector.

    2. B00497RC01
      B00497S Install in this Direction

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

  48. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B0049CZC01
      B00497S Install in this Direction

      Engage the claws to install the front door inside handle bezel plug as shown in the illustration.

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    Note

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

    Click here

  50. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  51. INSPECT POWER WINDOW OPERATION

    Click here

  52. INSPECT SRS WARNING LIGHT (w/ Airbag Sensor)

    Click here