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 RH side.

PROCEDURE


  1. INSTALL NO. 1 BLACK OUT TAPE

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  2. INSTALL FRONT DOOR PANEL CUSHION


    1. A004FJV

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

  3. INSTALL FRONT DOOR WEATHERSTRIP


    1. A004FTE

      Engage the 29 clips to install the front door weatherstrip.

    2. Engage the clip.

  4. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. A004G7OC02
      *a Body Panel
      *b Door Panel

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

      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 front door check to the body panel with the bolt.

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

  5. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A004FQRC03
      *a Snap

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

  6. 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. A004F40C01
      *a Grommet

      Engage the 2 claws and grommet to install the front door outside handle frame sub-assembly in the direction indicated by the arrow as shown in the illustration.

    3. Engage the grommet and 2 claws.

    4. A004E5Q

      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 }

  7. 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. A004F40C02
      *a Grommet

      Engage the 2 claws and grommet to install the front door outside handle frame sub-assembly in the direction indicated by the arrow as shown in the illustration.

    3. Engage the grommet and 2 claws.

    4. A004E5Q

      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. A004FZS

      Engage the 2 clamps.

  8. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD


    1. A004FKP

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

  9. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD


    1. A004GDY

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

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


    1. A004FHG

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

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


    1. A004FHG

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

    2. A004F2X

      Connect the connector.

    3. Engage the 3 claws and clamp.

  12. INSTALL FRONT DOOR LOCK ASSEMBLY

    Click here

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


    1. A004FHS

      Engage the 2 guides.

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

    3. A004FAR

      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.

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


    1. A004GAG

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

    2. A004E5S

      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.

  15. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP


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

    2. A004G11

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

  16. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. A004FXL

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

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

    2. Install the screw.

      Note

      Make sure to return the front door weatherstrip to its original condition after performing this step.

  17. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A004GFC

      Engage the guide to install the front door rear lower frame sub-assembly.

    2. Install the bolt.

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

  18. INSTALL FRONT DOOR GLASS RUN


    1. A004EKI

      Install the front door glass run.

  19. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY


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

    2. A004GA2E07
      Text in Illustration
      *a Temporary Bolt

      Install the temporary bolt to the front door window regulator sub-assembly.

    3. Insert the front door window regulator sub-assembly 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.

  20. 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. A004EKAE04

      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. A004F3G

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. A004G03

      Install the front door service hole cover.

  21. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the front door panel.

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

    3. A004GI8E02
      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.

  22. INSTALL FRONT DOOR OUTSIDE MOULDING (w/ Outside Moulding)

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

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

    Click here

  24. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  25. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  26. INSTALL FRONT DOOR WINDOW FRAME FRONT MOULDING

    Tech Tips

    Use the same procedure as for the LH side.

    Click here

  27. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP


    1. A004ENZ

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

  28. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A004G6F

      Engage the 4 guides to install the front door inside handle sub-assembly.

  29. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A004G6YE04
      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 assembly and the front door inside locking cable assembly to the front door inside handle.

    2. A004E3W

      Engage the 7 clips to install the front door trim board sub-assembly.

    3. A004F46

      Install the 3 screws.

    4. A004EKP

      Engage the claw and close the cover.

  30. INSTALL FRONT ARMREST BASE UPPER PANEL


    1. Connect the connector.

    2. A004F0U

      Engage the clip, 8 claws and 4 guides to install the front armrest base upper panel.

  31. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL


    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

  32. INSPECT POWER WINDOW OPERATION

    Click here