FRONT DOOR REASSEMBLY

Tech Tips

Use the same procedure for both the RH and LH sides.
The procedure described below is for the LH side.

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 Click here.

REPAIR INSTRUCTION

Clean the vehicle body surface.

Using a heat light, heat the vehicle body surface.

Heating Temperature
Item	Temperature
Vehicle Body	40 to 60°C (104 to 140°F)

Note

Do not heat the vehicle body excessively.

Wipe off any tape adhesive residue with cleaner.

Installation temperature
1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.
  Tech Tips
  - The most appropriate temperature for installing the tape is 25°C (77°F).
  - When the temperature is low, the tape becomes stiff and comes off easily. When the temperature is high, the tape elasticity increases.
Before installation
1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.
  
  Tech Tips
  
  Spray water on the shop floor to settle any dust.
Key points for handling the tape
1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.
  
  Note
  
  Do not bend the tape or leave it in high temperature places.

Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)

Note

Position the tape accurately to achieve a neat finish and to avoid peeling.
The tape cannot be reused because it deforms after removal.

To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not contact the vehicle body prematurely. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 3 to 7 cm (1.18 to 2.76 in.) per second.

Text in Illustration
*A	Pressing Forward	*B	Pulling
*1	Non-padded Side	*2	Padded Side
*3	Squeegee	*4	Black Out Tape
*5	Release Paper	-	-
*a	Side View	-	-

Reference Measurement
Area	Measurement
A	10 to 20 mm (0.394 to 0.787 in.)
B	30 to 70 mm/sec. (1.18 to 2.76 in./sec.)
C	40 to 50° (for pressing forward)
D	30 to 45° (for pulling)

Note

Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

Tech Tips

Either angle of the squeegee (pressing forward or pulling) is acceptable.
Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.

Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces)

Text in Illustration
*1	Squeegee
*2	Hem
*a	First
*b	Second
*c	Third

If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.

Tech Tips

When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

Key points for installation of the tape (how to use a squeegee and installation procedure for corners)
1. Remove the release paper and apply the tape carefully with your fingers.
2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.
Check after installation
1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.
  
  Note
  
  Do not reuse the tape.

INSTALL FRONT INNER BLACK OUT TAPE

Refer to the illustration to position a new front inner black out tape.

Text in Illustration
*A	LH Side	*B	RH Side
*a	Edge of Curved Surface	*b	Square
*c	Round	-	-

Standard Measurement
Dimension	Measurement
A	1.5 mm (0.0591 in.)
B	1.0 mm (0.0394 in.)

Remove the release paper and apply the front inner black out tape.

INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE

Refer to the illustration to position a new front door rear inner black out tape.

Text in Illustration
*A	LH Side	*B	RH Side
*a	Edge of Curved Surface	*b	Square
*c	Round	-	-

Standard Measurement
Dimension	Measurement
A	1.0 mm (0.0394 in.)
B	1.5 mm (0.0591 in.)

Remove the release paper and apply the front door rear inner black out tape.

INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

Engage the guide of the front door outside moulding sub-assembly to the door frame.

Using an air riveter or hand riveter with a nose piece, install the front door outside moulding sub-assembly with 7 new rivets.

Tech Tips

If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

Note

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

Text in Illustration
*1	Riveter
*2	Mandrel
*a	Incorrect

Confirm that the rivets are seated properly against the moulding.

Text in Illustration
*1	Riveter
*a	Incorrect

Do not tilt the riveter when installing the rivet to the moulding.
Do not leave any clearance between the rivet head and moulding.

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

Text in Illustration
*1	Riveter
*a	Incorrect

INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

Tech Tips

When installing a new front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light.

Heating Temperature
Item	Temperature
Vehicle Body	40 to 60°C (104 to 140°F)
Moulding	20 to 30°C (68 to 86°F)

Note

Do not heat the vehicle body or front door rear window frame moulding excessively.

Clean the vehicle body surface.
1. Using a heat light, heat the vehicle body surface.
2. Remove the double-sided tape from the vehicle body.
3. Wipe off any tape adhesive residue with cleaner.

Text in Illustration
*1	Double-sided Tape
*2	Caulking Sponge

Install a new front door rear window frame moulding.

Using a heat light, heat the vehicle body and front door rear window frame moulding.
Remove the release paper from the face of the front door rear window frame moulding.

Tech Tips

After removing the release paper, keep the exposed adhesive free from foreign matter.
Engage the guide and clip and install a new front door rear window frame moulding.

INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
1. Engage the guide and 6 claws to install the front door belt moulding assembly.
INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER
1. Install the front door front lower frame upper cover with the nut.
INSTALL FRONT DOOR LOWER FRAME GARNISH PAD
1. Install the front door lower frame garnish pad.
INSTALL FRONT DOOR PANEL CUSHION
1. Engage the claw to install a new front door panel cushion.
INSTALL FRONT DOOR NO. 2 WEATHERSTRIP
1. Engage the 9 clips to install the front door No. 2 weatherstrip.
INSTALL DOOR FRAME GARNISH
1. Engage the 3 claws to install the door frame garnish.
INSTALL FRONT DOOR WEATHERSTRIP
1. Clean the front door panel.
2. Text in Illustration
  
  *1 Double-sided Tape
  
  Engage the 21 clips and guide, to install a new front door weatherstrip.
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. 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 }
INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION
1. Clean the front door panel.
2. 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.
INSTALL FRONT DOOR LOCK OPEN ROD
1. Install the front door lock open rod as indicated by the arrows and in the order shown in the illustration.
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. 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. Engage the 3 clamps.
INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY
1. Install the front door inside locking cable assembly as shown in the illustration.
2. Engage the 3 claws as shown in the illustration.
INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
1. Install the front door lock remote control cable assembly as shown in the illustration.
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. Install a new door lock wiring harness seal to the front door lock assembly.
3. 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 }
INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Engage the 2 claws to install the front door rear outside handle pad.
INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Engage the 3 claws to install the front door front outside handle pad.
INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY
1. 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. Move the lever back in the direction indicated by the arrow in the illustration to lock the front door outside handle assembly.
4. Connect the connector.
5. Engage the 2 claws.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)
1. Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
1. 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. Install the hole plug.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)
1. 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. Install the hole plug.
INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
1. 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 }
INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY
1. 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 }
INSTALL FRONT DOOR GLASS RUN
1. Install the front door glass run.
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. 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.
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. 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 }
INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
1. Connect the cable to the negative (-) battery 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 negative (-) battery terminal.
4. Disconnect the multiplex network master switch assembly.
5. 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. Install the front door glass sub-assembly with the 2 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
7. Install the grommet.
INSTALL FRONT DOOR SERVICE HOLE COVER
1. Apply new butyl tape to the front door panel.
2. 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. Text in Illustration
  
  *A for LH Side
  
  Engage each clamp.
5. Connect the 2 connectors.
INSTALL FRONT DOOR ARMREST SET BRACKET
1. Install the front door armrest set bracket with the 2 screws.
INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
1. Install the front No. 1 speaker assembly with the 4 screws.
  
  Note
  
  Do not touch the speaker cone.
2. Connect the connector.
INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
1. Engage the 2 clips to install the front door lower frame bracket garnish.
INSTALL OUTER REAR VIEW MIRROR ASSEMBLY
1. Engage the clamp to temporarily install the outer rear view mirror assembly.
2. Install the outer rear view mirror assembly with the 3 nuts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL OUTER MIRROR INSTALL HOLE COVER
1. Engage the claw<A> as shown in the illustration.
2. Engage the claw<B> as shown in the illustration.
3. Install the outer mirror install hole cover with the screw.
4. w/o Memory:
  1. Connect the connector.
INSTALL OUTER MIRROR PROTECTOR
1. Text in Illustration
  
  *a Reference Point
  
  Install a new outer mirror protector while aligning it to the reference points on the front door panel.
INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)
1. Install the outer mirror control ECU assembly with the 2 screws.
2. Connect the 2 connectors.
INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel and Bamboo Panel)
1. Engage the claw.
2. Install the front door trim ornament sub-assembly with the screw.
3. Install the front door trim ornament assembly with the 11 screws.
4. w/ Illumination:
  1. Engage the 3 clamps.
INSTALL SEAT MEMORY SWITCH (w/ Memory)
1. Engage the 4 claws to install the seat memory switch to the front door trim board sub-assembly.
INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP
1. Install the front door inner glass weatherstrip.
INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Engage the 2 guides and claw to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Text in Illustration
*1	Bolt
*2	Nut

Text in Illustration
*a	Outside
*b	Inside

Text in Illustration
*1	Front Door Lock Open Rod

Text in Illustration
*1	Temporary Bolt

Text in Illustration
*a	Reference Point

Text in Illustration
*A	for LH Side

Text in Illustration
*a	Reference Point

INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

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.

w/ Memory:
1. Connect the connector.
w/ Illumination:
1. Connect the connector.
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.
Engage the 11 clips to temporary install the front door trim board sub-assembly.
Install the 3 screws to install the front door trim board sub-assembly.

INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION
1. Install the front door No. 1 stiffener cushion with the screw.
INSTALL COURTESY LIGHT ASSEMBLY
1. Connect the connector.
2. Text in Illustration
  
  *A for LH Side
  
  *B for RH Side
  
  Engage the claw to install the courtesy light assembly.
INSTALL DOOR PULL HANDLE COVER
1. Install the door pull handle cover.
INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)
1. Connect each connector.
2. Engage the 2 guides, 2 clips and 6 claws, to install the multiplex network master switch assembly with front door armrest base panel.
INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)
1. Connect each connector.
2. Engage the 2 guides, 2 clips and 6 claws, to install the power window regulator switch assembly with front door armrest base panel.
INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG
1. Engage the 3 claws to install the front door inside handle bezel plug.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INITIALIZE POWER WINDOW CONTROL SYSTEM

Click here
INSPECT POWER WINDOW OPERATION

Click here