FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The procedure described below 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 auxiliary battery negative (-) terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery negative (-) terminal notices before proceeding with work Click here.

  2. REPAIR INSTRUCTION

    Click here

  3. INSTALL FRONT INNER BLACK OUT TAPE

    Click here

  4. INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE

    Click here

  5. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Click here

  6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  8. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

    Click here

  9. INSTALL FRONT DOOR LOWER FRAME GARNISH PAD


    1. A0005L8

      Install the front door lower frame garnish pad.

  10. INSTALL FRONT DOOR PANEL CUSHION


    1. A0006UH

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

  11. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. A0005S3

      Engage the 9 clips to install the front door No. 2 weatherstrip.

  12. INSTALL DOOR FRAME GARNISH


    1. A0007MT

      Engage the 3 claws to install the door frame garnish.

  13. INSTALL FRONT DOOR WEATHERSTRIP


    1. Clean the front door panel.

    2. A000481E01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 21 clips and guide, to install a new front door weatherstrip.

  14. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A0007NFE07
      Text in Illustration
      *1 Bolt
      *2 Nut

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

      Torque:
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  15. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


    1. Clean the front door panel.

    2. A0005Y0E05
      Text in Illustration
      *1 Double-sided Tape

      Engage the 2 guides.

    3. Install a new front door No. 2 stiffener cushion with the 2 bolts.

  16. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A0003U9E03

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

  17. 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. A0003Z0E03
      Text in Illustration
      *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.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. A00068I

      Engage the 3 clamps.

  18. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A00050O

      Install the front door inside locking cable assembly as shown in the illustration.

    2. A0006XS

      Engage the 3 claws as shown in the illustration.

  19. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A0006Q6

      Install the front door lock remote control cable assembly as shown in the illustration.

  20. INSTALL FRONT DOOR LOCK ASSEMBLY

    Note


    • When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.

    • Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.

    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock assembly.


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

    2. When reusing the front door lock assembly:


      1. A00094O

        Install a new door lock wiring harness seal to the front door lock assembly.

    3. A0006DGE05
      Text in Illustration
      *1 Front Door Lock Open Rod

      Insert the front door lock open rod to the front door lock assembly.

    4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.

    5. Using a T30 "TORX" socket wrench, install the front door lock assembly with the 3 screws.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  21. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A0006LM

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

  22. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A0008ZD

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

  23. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A0006LW

      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. A0003I5

      Move the lever back in the direction indicated by the arrow in the illustration to lock the front door outside handle assembly.

    4. A00062I

      Connect the connector.

    5. Engage the 2 claws.

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


    1. A0007H4

      Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.

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


    1. A00071A

      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 }
    2. A0004KG

      Install the hole plug.

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


    1. A0003N2

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A0004PM

      Install the hole plug.

  27. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A00074J

      Engage the guide.

    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 FRONT LOWER FRAME SUB-ASSEMBLY


    1. A0003VW

      Engage the guide.

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

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

  29. INSTALL FRONT DOOR GLASS RUN


    1. A0006MU

      Install the front door glass run.

  30. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the power window regulator motor.


    1. A0003J4

      Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  31. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


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

    2. Install the temporary bolt to the front door window regulator assembly.

    3. A00072ME08
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the front door window regulator assembly.

    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:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  32. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

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

    4. Disconnect the multiplex network master switch assembly.

    5. A000745E04

      Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows and in the order shown in the illustration.

    6. A0005IP

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

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    7. A0009F3

      Install the grommet.

  33. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. A0005WBE04
      Text in Illustration
      *a Reference Point

      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. Attach 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.

    4. A0003TKE02
      Text in Illustration
      *A for LH Side

      Engage each clamp.

    5. Connect the 2 connectors.

  34. INSTALL FRONT DOOR ARMREST SET BRACKET


    1. A0008WY

      Install the front door armrest set bracket with the 2 screws.

  35. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  36. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. A0006PU

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

  37. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  38. INSTALL OUTER MIRROR INSTALL HOLE COVER

    Click here

  39. INSTALL OUTER MIRROR PROTECTOR

    Click here

  40. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)

    Click here

  41. INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel and Bamboo Panel)


    1. A0005HE

      Engage the claw.

    2. Install the front door trim ornament sub-assembly with the screw.

    3. A0009LA

      Install the front door trim ornament assembly with the 11 screws.

    4. w/ Illumination:


      1. A0006TO

        Engage the 3 clamps.

  42. INSTALL SEAT MEMORY SWITCH (w/ Memory)

    Click here

  43. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A0006XN

      Install the front door inner glass weatherstrip.

  44. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A0009HC

      Engage the 2 guides and claw to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

  45. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A0008XUE04
      Text in Illustration
      *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. w/ Memory:


      1. Connect the connector.

    3. w/ Illumination:


      1. Connect the connector.

    4. A00041ZE01
      Text in Illustration
      *1 Reference Boss

      Engage the front door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

    5. A0006C5

      Engage the 11 clips to temporarily install the front door trim board sub-assembly.

    6. A0006P1

      Install the 3 screws to install the front door trim board sub-assembly.

  46. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. A0008MG

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

  47. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  48. INSTALL DOOR PULL HANDLE COVER


    1. A0008UH

      Install the door pull handle cover.

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


    1. Connect each connector.

    2. A0008V3

      Engage the 2 guides, 2 clips and 6 claws, to install the multiplex network master switch assembly with front door armrest base panel.

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


    1. Connect each connector.

    2. A0007MG

      Engage the 2 guides, 2 clips and 6 claws, to install the power window regulator switch assembly with front door armrest base panel.

  51. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A00084O

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

  52. 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.

  53. INSTALL LUGGAGE TRIM SERVICE HOLE COVER

    Click here

  54. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  55. INSPECT POWER WINDOW OPERATION

    Click here