FRONT DOOR INSTALLATION

Tech Tips


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

  • The procedure listed below is for the LH side.

  • A bolt without a torque specification is shown in the standard bolt chart Click here.


  1. INSTALL FRONT DOOR CHECK ASSEMBLY LH


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

    2. When reusing a bolt labeled B:


      1. Clean the threads of the bolt labeled B with non-residue solvent.

      2. Apply adhesive to the threads of the bolt labeled B.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. A01J4YDE01
      Text in Illustration
      *1 Bolt A
      *2 Bolt B

      Install the front door check with the 2 bolts labeled A and the bolt labeled B.

      Torque:
      Bolt A
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      Bolt B
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  2. INSTALL FRONT DOOR WEATHERSTRIP LH

    Tech Tips

    When installing the front door weatherstrip, heat the front door panel using a heat light.

    Standard
    Item Temperature
    Front Door Panel 40 to 60°C (104 to 140°F)

    Note

    Do not heat the front door panel excessively.


    1. Clean the front door panel surface.


      1. Using a heat light, heat the front door panel surface.

      2. Remove the double-sided tape from the front door panel surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new front door weatherstrip.


      1. Remove the peeling paper from the face of the front door weatherstrip.

        Tech Tips

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

      2. Attach the 33 clips to install the front door weatherstrip.

        Tech Tips

        Press the front door weatherstrip firmly to install it.

      3. Install the clip.

  3. INSTALL FRONT DOOR PANEL CUSHION


    1. Install a new front door panel cushion.

  4. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


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

  5. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


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

  6. INSTALL FRONT DOOR LOCK OPEN ROD LH


    1. A01J6DQE01
      Text in Illustration
      *1 Snap

      Install the front door lock open rod to the front door outside handle frame.

    2. Rotate the snap in the direction indicated by the arrow in the illustration to attach the snap to the front door lock open rod.

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


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

    2. Attach the claw to install the front door outside handle frame.

    3. Using a T30 "TORX" socket wrench, install the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 36 in.*lbf }

  8. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


    1. A01J4ZR

      Install the front door outside handle by moving it in the direction indicated by the arrow shown in the illustration.

  9. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH


    1. Install the front door inside locking cable.

    2. Attach the 3 claws to close the cover.

  10. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the front door lock remote control cable.

  11. INSTALL FRONT DOOR LOCK ASSEMBLY LH


    1. Install a new door lock wiring harness seal to the front door lock.

      Note


      • When reusing the removed front door lock, replace the door lock wiring harness seal on the connector with a new one.

      • Do not allow grease or dust to adhere to the surface of the connector which contacts the door lock wiring harness seal.

      • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may allow water into the connection. This may result in a malfunction of the front door lock.

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

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

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

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

    5. Connect the connector.

  12. INSTALL FRONT DOOR OUTSIDE HANDLE COVER


    1. Attach the 2 claws to install the front door outside handle cover to the door key cylinder.

    2. Using a T30 "TORX" socket wrench, install the front door outside handle cover together with the door key cylinder with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 36 in.*lbf }

    3. Install the hole plug.

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


    1. Install the front door rear lower frame with the 2 nuts.

  14. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH


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

    2. Using a T25 "TORX" socket wrench, install the power window regulator motor assembly LH with the 3 screws.

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

  15. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


    1. A01J73M

      Apply MP grease to the sliding and rotating areas of the front door window regulator.

    2. A01J7FNE01

      Temporarily install the temporary bolt to the front door window regulator.

    3. Install the front door window regulator with the 5 bolts, and then tighten the temporary bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Text in Illustration
      *1 Temporary Bolt

      Note

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

    4. Connect the connector.

  16. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


      1. Using a heat light, heat the vehicle body surface.

      2. Wipe off any tape adhesive residue with cleaner.

    2. 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 to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is higher than 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape 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 turns stiff and falls off easily. When the temperature is high, the tape loses elasticity.

    3. Before installation.


      1. Make sure any dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame) is removed, and that the surface is smooth. If the surface is rough 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.

    4. 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 level.

        Note

        Do not bend the tape or leave it in a place with a high temperature.

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

      Note


      • Position the tape with a high level of accuracy to achieve a neat finish and to avoid peeling.

      • The tape cannot be reused because it deforms and will not fit after removal.


      1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee 40 to 50° (for pressing forward) or 30 to 45° (for pulling) from the vehicle body surface and press with a force of 20 to 30 N (2 to 3 kgf) while moving the squeegee at a constant slow speed of 3 to 7 cm (1.2 to 2.8 in.) per second.

        A01J4KGE02

        Note

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

        Tech Tips


        • Either angle of the squeegee (for pressing forward or for pulling) is acceptable.

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.393 to 0.787 in.) from the edge of the squeegee.

        Text in Illustration
        *A Pressing *B Pulling
        *1 Squeegee *2 Black Out Tape
        *3 Release Paper - -
        *a Sectional View *b Non-padded Side
        *c Padded Side - -
    6. A01J2YYE02
      Text in Illustration
      *1 Squeegee
      *a First
      *b Second
      *c Third

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


      1. If it is difficult to press the tape, press 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.

    7. Key points for the installation of the tape (how to use a squeegee and the 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 to avoid wrinkles in the tape and achieve a neat finish.

    8. Check after installation.


      1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, apply new tape.

        Note

        Do not reuse the tape.

  17. INSTALL NO. 1 BLACK OUT TAPE LH

    Tech Tips

    When installing the No. 1 black out tape, heat the vehicle body and No. 1 black out tape using a heat light.

    Standard
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    No. 1 Black Out Tape 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or No. 1 black out tape excessively.


    1. A01J7HTE01
      Text in Illustration
      *1 No. 1 Black Out Tape
      *a Line A
      *b Line B

      Align the perforations of the release paper of new No. 1 black out tape with line A and line B as shown in the illustration, and then apply the No. 1 black out tape.

    2. Remove the release paper from the No. 1 black out tape.

  18. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run.

  19. INSTALL FRONT DOOR OUTER GLASS WEATHERSTRIP ASSEMBLY LH


    1. Attach the 5 claws to install the front door outer glass weatherstrip.

  20. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH


    1. Temporarily install the power window regulator master switch assembly with front door armrest base panel.

    2. Connect the cable to the negative (-) battery terminal.

    3. Operate the front door window regulator so that the front door glass can be installed.

    4. Disconnect the cable from the negative (-) battery terminal.

      Note

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

    5. Remove the power window regulator master switch assembly with front door armrest base panel.

    6. A01J51BE01

      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.

    7. Install the front door glass with the 2 bolts.

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

  21. INSTALL FRONT DOOR SERVICE HOLE COVER LH


    1. Apply new butyl tape to the front door panel.

    2. A01J482E01
      Text in Illustration
      *a Reference Point

      Pass the front door inside locking cable, front door lock remote control cable and wire harness through a new front door service hole cover, and then install the front door service hole cover using the reference points on the front door panel.

  22. INSTALL FRONT DOOR NO. 1 TRIM BRACKET


    1. Install the front door No. 1 trim bracket with the 2 screws.

  23. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. A01J3N7

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

    2. Attach the 2 guides as indicated by the arrow in the illustration, and then attach the claw to install the front door inside handle.

  24. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    A01J4FP

    1. Install the outer rear view mirror assembly LH with the 3 nuts.

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

    2. w/ Power Mirror Control System:

      Connect the connector.

  25. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


    1. Install a nose piece to an air riveter or hand riveter. Then insert the mandrel part of a new φ4 mm waterproof rivet into the nose piece.

    2. A01J65Z

      Using an air riveter or hand riveter, install the speaker with 3 new rivets.

      Note


      • A01J68OE19

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

        Text in Illustration
        *1 Mandrel
        *2 Riveter
        *a INCORRECT
        *b CORRECT
      • A01J3QWE19

        Confirm that the rivets are seated properly against the speaker.

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT

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

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

      • A01J6COE17

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

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT

    3. Connect the connector.

  26. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY


    1. Install the front No. 2 speaker assembly with the screw.

    2. Connect the connector.

  27. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. A01J3QY

      Install the front door inner glass weatherstrip to the front door trim board and fold down the 7 claws in the directions indicated by the arrows in the illustration.

  28. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


    1. Attach the 8 clips to install the front door trim board.

    2. Install the screw and clip.

  29. INSTALL DOOR PULL HANDLE


    1. Install the door pull handle with the screw.

  30. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH


    1. Attach the 2 clips to install the front door lower frame bracket garnish.

  31. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL


    1. Connect the connector.

    2. Attach the 4 claws and 2 clips to install the power window regulator switch assembly with front door armrest base panel.

  32. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Passenger Side)


    1. Connect the connector.

    2. Attach the 4 claws and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.

  33. CONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  34. INITIALIZE POWER WINDOW CONTROL SYSTEM (w/ Jam Protection Function)

    Click here