FRONT DOOR REASSEMBLY

Tech Tips


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

  • The procedure described below is for the RH side.


  1. APPLY BODY GREASE

  2. INSTALL CUSHION


    1. A0118IW

      Install the 2 cushions onto the door panel.

  3. INSTALL FRONT DOOR WEATHERSTRIP


    1. A011BAN

      Engage the 25 clips and install the front door weatherstrip.

  4. INSTALL ELECTRICAL KEY WIRE HARNESS (w/ Entry and Start System)


    1. A011BX2

      Engage the clamp and install the electrical key wire harness as shown in the illustration.

  5. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Entry and Start System)


    1. A011BUO

      Apply MP grease to the sliding areas of the front door outside handle frame.

    2. Slide the front door outside handle frame to install it.

    3. Using "TORX" socket wrench T30, install the front outside handle frame with the screw.

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

  6. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Entry and Start System)


    1. Apply MP grease to the sliding areas of the front door outside handle frame.

    2. A011BGW

      Slide the front door outside handle frame to install it.

    3. Using "TORX" socket wrench T30, install the front outside handle frame with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. A011AS5

      Connect the connector.

    5. Engage the 4 clamps.

  7. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD


    1. A011779

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

  8. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD


    1. A0118R3

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

  9. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Entry and Start System)


    1. A0118RD

      Pushing the front door outside handle in the direction of the arrow mark shown in the illustration, install the front door outside handle.

    2. A0119F4

      Pull down the door handle holder as shown by the arrow and lock the front door outside handle.

  10. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Entry and Start System)


    1. A0118RD

      Pushing the front door outside handle in the direction of the arrow mark shown in the illustration, install the front door outside handle.

    2. A011AEJ

      Pull down the door handle holder as shown by the arrow and lock the front door outside handle.

    3. A011A4F

      Connect the connector.

    4. Engage the 4 claws and install the connector cover.

    5. Engage the clamp.

  11. INSTALL FRONT DOOR LOCK ASSEMBLY


    1. Apply MP grease to the sliding and rotating areas of the front door lock.

    2. A011BC7

      Install a new door lock wire harness seal.

      Note


      • If reusing the door lock replace the wire harness seal with new seal.

      • Make sure that no grease and dirt adheres to the wire harness seal surface.

    3. Insert the front door lock open rod into the front door lock, and set it to the front door outside handle frame.

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

    5. Apply adhesive to the threads of the screws.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

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


    1. A011BSC

      Engage the 2 claws and install the lock cylinder.

    2. A011BGE

      Using "TORX" socket wrench T30, install the cover.

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

    3. Install the hole plug.

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


    1. A0117E5

      Using "TORX" socket wrench T30, install the cover.

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

    2. Install the hole plug.

  14. INSTALL FRONT DOOR FRAME REAR LOWER SUB-ASSEMBLY


    1. A0118IB

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

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

  15. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. A0119QS

      Install the front door check onto the door panel with the 2 bolts.

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

    3. Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the front door check onto the body panel with the bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  16. INSTALL FRONT DOOR STIFFENER CUSHION


    1. A0117M3E02
      Text in Illustration
      *1 Double-sided Tape

      Install a new front door stiffener cushion with the 2 bolts and apply thorough pressure to the sections with double-sided tape.

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

  17. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY


    1. A0117ERE01

      Install the nut (C), engage the clamp, and install the front door window regulator.

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

    2. Install the 3 nuts (B) and engage the 3 clamps.

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

    3. Install the 3 bolts.

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

    4. Engage the clamp (A).

    5. Install the regulator wire to the holder.

    6. Connect the connector.

  18. INSTALL FRONT DOOR GLASS RUN


    1. A0117XE

      Install the front door glass run.

  19. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. A011B1S

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

      Note

      Do not damage the front door glass.

    2. A011BDT

      Install the front door glass onto the front door window regulator with the 2 bolts.

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

  20. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. A011AFV

      Apply butyl tape to the door panel, and then install a new front door service hole cover as shown in the illustration.

      Tech Tips


      • When installing the service hole cover, pull the links and connectors out through the service hole.

      • There should be no wrinkles or folds after attaching the service hole cover.

      • After attaching the service hole cover, check the quality of the seal.

    2. A0118VE

      Engage the clamps.

    3. Install the ground wire with the bolt.

    4. Connect the connector.

  21. INSTALL SIDE AIRBAG SENSOR


    1. Confirm that the ignition switch off.

    2. Confirm 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.

    3. A011BGKE01

      Engage the guide and install the airbag sensor with the bolt.

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

      Note


      • Do not use a side airbag sensor that has been dropped.

      • Do not subject the side airbag sensor to any impact or force.

    4. Confirm that there is no looseness by shaking the side airbag sensor.

    5. A01173VE01
      Text in Illustration
      *1 Outer Housing

      Connect the airbag connector.

  22. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side Click here.

  23. INSTALL FRONT DOOR WINDOW FRAME REAR MOULDING

    Tech Tips

    Use the same procedure as for the LH side Click here.

  24. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side Click here.

  25. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


    1. A011AHF

      Using an air riveter or hand riveter, install the front No. 1 speaker with 3 new strike rivets.

      Tech Tips

      Install the new strike rivets in the order shown in the illustration.

      Note

      A01188R

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

      • A0118T6

        Confirm that the rivets are seated properly against the speaker.

      • Do not tilt the riveter when installing the rivet into the speaker.

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

      • A0119SW

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

    2. A011921

      Connect the connector.

  26. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP


    1. A011AS7

      Install the front door glass inner weatherstrip.

  27. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY

    A011BD5

    1. Engage the 3 claws and install the front No. 2 speaker.

  28. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A011AVS

      Engage the 2 claws and install the front door inside handle.

  29. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A011AHT

      Connect the front door lock remote control cable and the front door inside locking cable.

    2. A011928

      Engage the 6 claws and 10 clips and install the front door trim board.

    3. A011AF2

      Tighten the 3 screws.

    4. Connect the connector.

  30. INSTALL DOOR SPEAKER GRILLE BASE


    1. A011BDB

      Engage the 4 claws and install the door speaker grille base.

  31. INSTALL DOOR ASSIST GRIP COVER


    1. A0118FZ

      Engage the 6 claws and install the door assist grip cover.

  32. INSTALL FRONT DOOR INSIDE HANDLE BEZEL


    1. A011BD7

      Engage the 4 claws and install the front door inside handle bezel.

  33. INSTALL FRONT ARMREST BASE UPPER PANEL (w/o Screw)


    1. Connect the connector.

    2. A0118ZL

      Engage the 6 claws and install the front armrest base upper panel.

  34. INSTALL FRONT ARMREST BASE UPPER PANEL (w/ Screw)


    1. A011BMF

      Engage the claw and install the door armrest cap.

    2. Connect the connector.

    3. A011B81

      Engage the 6 claws and install the front armrest base upper panel.

    4. A01189G

      Install the screw.

    5. A01188H

      Engage the claw and close the door armrest cap.

  35. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. A011AD3

      Engage the 2 guides and the clip and install the front door lower frame bracket garnish.

  36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 49 in.*lbf }

  37. INSPECT SRS WARNING LIGHT

    Click here

  38. INSPECT POWER WINDOW OPERATION

    Click here