FRONT DOOR REASSEMBLY

Tech Tips


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

  • The procedure listed below is for the LH side.


  1. INSTALL FRONT DOOR WEATHERSTRIP LH

    Tech Tips

    When installing the front door weatherstrip, heat the vehicle body and front door weatherstrip using a heat light.

    Standard
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Front Door Weatherstrip 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or front door weatherstrip excessively.


    1. 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.

    2. Install the front door weatherstrip LH.


      1. Using a heat light, heat the vehicle body and a new front door weatherstrip LH.

      2. Remove the peeling paper from the face of the front door weatherstrip LH.

        Tech Tips

        After removing the peeling paper, keep the exposed adhesive free from foreign matter.

      3. Attach the 21 clips to install a new front door weatherstrip LH.

        Tech Tips


        • If clips are damaged during installation, replace them.

        • Press the front door weatherstrip LH firmly to install it.

  2. INSTALL FRONT DOOR CHECK ASSEMBLY LH


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

    2. Install the front door check assembly LH to the door panel with the 2 nuts.

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

    3. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the bolt.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  3. INSTALL FRONT NO. 2 DOOR STIFFENER CUSHION

    Tech Tips

    When installing the front No. 2 door stiffener cushion, heat the vehicle body and front No. 2 door stiffener cushion using a heat light.

    Standard
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Front No. 2 Door Stiffener Cushion 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or front No. 2 door stiffener cushion excessively.


    1. Clean the installation 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.

    2. Install a new front No. 2 door stiffener cushion.


      1. Using a heat light, heat the vehicle body and a new front No. 2 door stiffener cushion.

      2. Remove the peeling paper from the face of the front No. 2 door stiffener cushion.

        Tech Tips

        After removing the peeling paper, keep the exposed adhesive free from foreign matter.

      3. Attach the 2 clamps to install the door stiffener cushion.

        Tech Tips

        Press the front No. 2 door stiffener cushion firmly to install it.

      4. Install the 2 bolts.

  4. INSTALL DOOR ELECTRICAL KEY OSCILLATOR


    1. A01EN5J

      Install the door electrical key oscillator with the screw.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

  5. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. A01EN8Q

      Install the front door lock open rod LH as shown in the illustration.

  6. INSTALL NO. 2 ELECTRICAL KEY WIRE HARNESS


    1. Connect the connector.

    2. Attach the 3 clamps to install the No. 2 electrical key wire harness to the front door outside handle frame sub-assembly.

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


    1. A01ENBC

      Attach the 2 claws to install the front door outside handle frame sub-assembly LH.

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

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

      Note

      A cover should be inserted between the screw and door panel.

  8. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the front door inside locking cable assembly LH.

    2. Attach the 3 claws.

  9. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the front door lock remote control cable assembly LH.

  10. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    A01ER8D

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

    2. Insert the front door lock open rod into the front door lock assembly.

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

    4. Using a T30 "TORX" wrench, install the door lock with the 3 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  11. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH


    1. Attach the 2 claws to install the front door rear outside handle pad LH.

  12. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH


    1. Attach the 3 claws to install the front door front outside handle pad LH.

  13. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A01EMXE

      Pull and hold the bell crank lever of the frame.

    2. Install the front door outside handle assembly LH by pushing it in the direction of the arrow in the illustration.

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

    4. Connect the connector.

  14. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH


    1. A01EP98

      Attach the 2 claws to install the front door outside handle cover LH to the front door lock cylinder.

    2. Using a T30 "TORX" socket, install the front door outside handle cover LH (with the door lock cylinder) with the screw.

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

    3. Install the hole plug.

  15. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH


    1. A01EOBH

      Apply MP grease to the sliding and rotating areas of the regulator motor.

    2. Using a T25 "TORX" driver, install the motor 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.

  16. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. A01EOK1E05
      Text in Illustration
      *1 Temporary Bolt

      Apply MP grease to the sliding and rotating areas of the front door window regulator sub-assembly LH.

      Note

      Do not apply grease to the spring of the front door window regulator sub-assembly LH.

    2. Temporarily install the temporary bolt onto the front door window regulator sub-assembly LH.

    3. Insert the front door window regulator sub-assembly LH into the door panel. Use the temporary bolt to hang the front door window regulator sub-assembly LH on the door panel.

      Note

      Be careful not to drop the front door window regulator sub-assembly LH as it may become damaged.

    4. Temporarily install the front door window regulator sub-assembly LH with the 5 bolts.

    5. Tighten the 6 bolts in the order shown in the illustration.

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

  17. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH


    1. 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 surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new window frame moulding.


      1. Using a heat light, heat a new window frame moulding and the vehicle body surface.

      2. Remove the peeling paper from the face of the window frame moulding.

        Tech Tips

        After removing the peeling paper, keep the exposed adhesive free from foreign matter.

      3. A01EOX4E02

        Attach the clip and double-sided tape to install the window frame moulding.

        Tech Tips

        Press the window frame moulding firmly to install it.

  18. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

    A01EO7V

    1. Attach the claw to install the belt moulding.

  19. INSTALL LOWER DOOR FRAME GARNISH LH


    1. Attach the clip to install a new lower door frame garnish LH.

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


    1. Install the front door rear lower frame sub-assembly LH with the bolt.

  21. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run LH.

  22. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. A01EOQ4

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

      Note

      Be careful not to damage the glass.

    2. Install the front door glass sub-assembly LH to the front door window regulator sub-assembly LH with the 2 bolts.

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

  23. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. A01EQVU

      Apply butyl tape to the door.

    2. Pass the front door lock remote control cable assembly LH and front door inside locking cable assembly LH through a new front door service hole cover LH.

      Note


      • When installing the front door service hole cover LH, pull the links and connectors through the front door service hole cover LH.

      • 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 sealing quality.

    3. A01EMWJE01

      Connect the 2 connectors.

    4. Attach the 7 clamps.

    5. Install the bolt as shown in the illustration.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  24. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH


    1. A01EN45

      Check that the engine switch is off.

    2. Check that the cable is disconnected from the battery negative (-) terminal.

      CAUTION:

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

      Note

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

    3. Install the side airbag sensor with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Note


      • If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.

      • When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts.

    4. Check that there is no looseness in the installation parts of the side airbag sensor.

    5. Connect the connector.

  25. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


    1. Connect the speaker connector.

    2. Install the speaker with the 4 screws.

      Note

      Do not touch the cone part of the speaker.

      A01EPVNE01

  26. INSTALL DOOR TRIM COVER LH


    1. Attach the 7 clips to install the door trim cover LH.

  27. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION


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

  28. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY


    1. Connect the 2 connectors.

    2. Install the outer mirror control ECU assembly with the 2 screws.

  29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    A01ERRFE02

    1. Attach the claw to install the mirror.

    2. Install the 3 nuts.

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

    3. Attach the clamp.

    4. Connect the connector.

  30. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Install the inside handle to the trim board with the 5 screws.

    2. Install the front door armrest assembly to the trim board with the 17 screws.

  31. INSTALL SEAT MEMORY SWITCH


    1. A01EN3N

      Attach the 4 claws to install the seat memory switch.

    2. A01EQ2B

      Attach the 2 claws to install the front door trim ornament.

    3. Install the 4 screws.

  32. INSTALL FRONT DOOR WIRING SUB-ASSEMBLY RH


    1. Connect the connector.

    2. Attach the clamp to install the front door wiring sub-assembly RH.

  33. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH


    1. A01ERAY

      Attach the 2 claws and clamp to install the light.

  34. INSTALL FRONT INNER DOOR GLASS WEATHERSTRIP LH


    1. A01EPGL

      Attach the 4 claws to install the front inner door glass weatherstrip LH.

  35. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Connect the connector.

    2. A01EO3L

      Connect the front door lock remote control cable assembly LH and front door inside locking cable assembly LH to the front door inside handle sub-assembly LH.

    3. A01EMZN

      Attach the 4 claws and 14 clips to install the front door trim board sub-assembly LH.

    4. Install the 2 screws.

  36. INSTALL FRONT LOWER DOOR ARMREST BASE PANEL LH


    1. Install the front lower door armrest base panel LH with the 3 screws.

  37. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY


    1. Connect the connector.

    2. A01EP3L

      Attach the 5 claws to install the armrest base panel.

  38. INSTALL FRONT UPPER ARMREST BASE PANEL LH


    1. Connect the connector.

    2. Attach the 5 claws to install the front upper armrest base panel LH.

  39. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


    1. Attach the 3 claws to install the front door inside handle bezel plug LH.

  40. INSTALL COURTESY LIGHT ASSEMBLY


    1. A01EPPJ

      Connect the connector.

    2. Attach the claw of the courtesy light to the front door trim.

  41. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH


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

  42. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH


    1. Attach the 3 clamps and 11 clips to install the front door outside moulding sub-assembly LH.

  43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  44. CHECK SRS WARNING LIGHT

    Click here

  45. INSTALL ENGINE ROOM SIDE COVER LH


    1. Install the engine room side cover LH with the 7 clips.