FRONT DOOR REASSEMBLY

PROCEDURE


  1. APPLY BODY GREASE

  2. INSTALL NO. 1 BLACK OUT TAPE

    Tech Tips

    Use the same procedure as for the LH side Click here

  3. INSTALL FRONT DOOR PANEL CUSHION


    1. A01V20Z

      Install the 2 front door panel cushions onto the door panel.

  4. INSTALL FRONT DOOR WEATHERSTRIP


    1. A01V1G8

      Engage the 29 clips and install the front door weatherstrip.

    2. Engage the clip.

  5. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. A01UYHG

      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 }

  6. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A01UYMGE01
      Text in Illustration
      *1 Snap

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

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


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

    2. A01V07ME01
      Text in Illustration
      *1 Grommet

      Slide the front door outside handle frame to install it.

    3. Engage the grommet and 2 claws.

    4. A01V1CA

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

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

  8. 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. A01V07ME01
      Text in Illustration
      *1 Grommet

      Slide the front door outside handle frame to install it.

    3. Engage the grommet and 2 claws.

    4. A01V1CA

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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    5. A01UYXE

      Engage the 2 clamps.

  9. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD


    1. A01V1ZP

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

  10. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD


    1. A01UZFT

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

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


    1. A01V1KV

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

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


    1. A01V1KV

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

    2. A01V0VH

      Connect the connector.

    3. Engage the 3 claws and clamp.

  13. INSTALL FRONT DOOR LOCK ASSEMBLY

    Click here

  14. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (w/ Lock Cylinder)


    1. A01UYP9

      Engage the 2 guides.

    2. Engage the claw and install the front door outside handle cover.

    3. A01V11Z

      Temporarily install the front door outside handle cover.

    4. Using a T30 "TORX" socket wrench, install the front door outside handle cover.

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

    5. Install the hole plug.

  15. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (w/o Lock Cylinder)


    1. A01V0YU

      Engage the 2 claws and temporarily install the front door outside handle cover.

    2. A01V0Y9

      Using a T30 "TORX" socket wrench, install the front door outside handle cover.

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

    3. Install the hole plug.

  16. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP


    1. Install the front door fix window glass onto the front door fix window weatherstrip.

    2. A01V1EC

      Slide the front door fix window weatherstrip, in the direction indicated by the arrow in the illustration, to install it.

  17. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. A01UZID

      Install the front door front lower frame with the 2 bolts and screw.

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

  18. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A01UYIG

      Engage the guide.

    2. Install the front door rear lower frame with the bolt.

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

  19. INSTALL FRONT DOOR GLASS RUN


    1. A01V019

      Install the front door glass run.

  20. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/ Power Window)


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

    2. Install the temporary bolt.

    3. A01V1YME07
      Text in Illustration
      *1 Temporary Bolt

      Insert the front door window regulator into the door panel. Use the temporary bolt to hang the front door window regulator on the door panel.

    4. Tighten the 3 bolts and the temporary bolt in the order shown in the illustration.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    5. Install the front door window regulator with the 2 bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    6. Connect the connector.

  21. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/o Power Window)


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

    2. Install the temporary bolt.

    3. A01V0PQE06
      Text in Illustration
      *1 Temporary Bolt

      Insert the front door window regulator into the door panel. Use the temporary bolt to hang the front door window regulator on the door panel.

    4. Tighten the 2 bolts and temporary bolt in the order shown in the illustration.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    5. Install the front door window regulator with the 2 bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

  22. INSTALL FRONT DOOR GLASS NO. 1 CHANNEL FILLER


    1. Apply soapy water to a new front door glass channel filler.

    2. A01UYDFE01
      Text in Illustration
      *a Front Side
      *b Rear Side

      Install the front door glass channel filler as shown in the illustration.

  23. INSTALL FRONT DOOR GLASS NO. 1 CHANNEL


    1. Apply soapy water to a front door glass channel.

    2. A01UZ7WE01
      Text in Illustration
      *a Front Side
      *b Rear Side

      Using a plastic-faced hammer, tap the channel onto the glass to install the glass channel.

      Note


      • Be careful not to damage the glass or glass channel.

      • Make sure the position of the front door glass channel filler does not change.

  24. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the power window regulator switch and move the front door glass so that the door glass bolt holes can be seen.

    3. Disconnect the cable from the negative (-) auxiliary battery terminal and the power window regulator switch.

    4. A01UYSJE04

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

      Note

      Do not damage the front door glass.

    5. A01UXTZ

      Install the front door glass with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. A01V1ZZ

      Install the front door service hole cover.

  25. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the front door panel.

    2. Pass the front door lock remote control cable, front door inside locking cable and each connector through a new front door service hole cover.

    3. A01V0TDE02
      Text in Illustration
      *a Reference Point

      Install a new front door service hole cover according to the reference points on the front door panel.

      Tech Tips

      Securely install the front door service hole cover taking care to prevent wrinkles.

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

    Click here

  27. INSTALL FRONT SPEAKER COVER (w/o Front Speaker)


    1. A01V0DSE02

      Using an air riveter or hand riveter, install the front speaker cover onto the front door panel with 3 new strike rivets.

      Tech Tips

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

      Note


      • A01UZ77

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

      • A01UZA9

        Confirm that the rivets are seated properly against the speaker cover.

      • Do not tilt the riveter when installing the rivet onto the speaker cover.

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

      • A01V0RL

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

    2. Connect the connector.

  28. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side Click here

  29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side Click here

  30. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING

    Tech Tips

    Use the same procedure as for the LH side Click here

  31. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP


    1. A01V03P

      Engage the 7 claws and install the front door glass inner weatherstrip as shown in the illustration.

  32. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01UZON

      Engage the 4 guides and install the front door inside handle.

  33. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A01UZRXE01
      Text in Illustration
      *1 Front Door Lock Remote Control Cable Assembly
      *2 Front Door Inside Locking Cable Assembly

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

    2. A01UZPX

      Engage the 7 clips and install the front door trim board.

    3. A01V215

      Install the 3 screws.

    4. A01V0GH

      Engage the claw and close the cover.

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


    1. Connect the connector.

    2. A01UYIW

      Engage the 9 claws and 4 guides, and install the front armrest base upper panel.

  35. INSTALL FRONT ARMREST BASE UPPER PANEL (w/o Power Window)


    1. Connect the connector.

      Tech Tips

      If the armrest base upper panel is equipped with door lock switch, connect the connector.

    2. A01UZRY

      Engage the 6 claws and 3 guides, and install the front armrest base upper panel.

  36. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)


    1. A01V05BE01
      Text in Illustration
      *a Inside of Vehicle

      Install the window regulator handle plate.

    2. Open all the windows.

    3. A01UY6XE01
      Text in Illustration
      *a Assemble with Glass in Fully Open Position

      Install the front door window regulator handle with clip at the angle shown in the illustration.

  37. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL (w/ Power Window)


    1. Connect the cable to negative auxiliary battery terminal.

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

      Note

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

    2. Install the front floor cover RH (for Front Floor Cover Type A). Click here

    3. Install the front floor cover RH (for Front Floor Cover Type B). Click here

    4. Install the center front floor cover (for Front Floor Cover Type B). Click here

  38. INSPECT POWER WINDOW OPERATION (w/ Power Window)

    Click here