FRONT DOOR REASSEMBLY

REPAIR INSTRUCTION

Clean the vehicle body surface.

Using a heat light, heat the vehicle body surface.

Heating Temperature
Item	Temperature
Vehicle Body	40 to 60°C (104 to 140°F)

Note

Do not heat the vehicle body excessively.

Wipe off any tape adhesive residue with cleaner.

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 up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down 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 comes off easily. When the temperature is high, the tape looses elasticity.
Before installation
1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness 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.
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 high temperature places.
Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)
Note
- Position the tape accurately to achieve a neat finish and to avoid peeling.
- The tape cannot be reused because it deforms and will not fit any more after being removed.
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 at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 3 to 7 cm (1.18 to 2.76 in.) per second.
  
  Note
  
  Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.
  Tech Tips
  
  Either angle of the squeegee (pressing forward or pulling) is acceptable.
  
  Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.
Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces)
1. If it is difficult to apply the tape, install 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.
Key points for installation of the tape (how to use a squeegee and 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, avoiding wrinkles on the tape to achieve a neat finish.
Check after installation
1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.
  
  Note
  
  Do not reuse the tape.

INSTALL NO. 1 BLACK OUT TAPE

Remove the portion of the No. 1 black out tape at the perforation as shown in the illustration.

Refer to the illustration to position the No. 1 black out tape.

Standard Measurement
Dimension	Measurement
A	2 to 4 mm (0.0787 to 0.157 in.)
B	4 to 6 mm (0.157 to 0.236 in.)

Remove the release paper and apply the tape.

INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

Refer to the illustration to position the front door lower outside strip.

Standard Measurement
Dimension	Measurement
A	2.0 mm (0.0787 in.)

Remove the release paper and apply the strip.

INSTALL FRONT DOOR REAR OUTSIDE STRIPE

Refer to the illustration to position the front door rear outside strip.

Standard Measurement
Dimension	Measurement
A	2.0 mm (0.0787 in.)

Remove the release paper and apply the strip.

INSTALL FRONT DOOR OUTSIDE STRIPE

Refer to the illustration to position the front door outside strip.

Standard Measurement
Dimension	Measurement
A	2.0 mm (0.0787 in.)

Remove the release paper and apply the strip.

INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

Tech Tips

When installing the front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light.

Heating Temperature
Item	Temperature
Vehicle Body	40 to 60°C (104 to 140°F)
Moulding	20 to 30°C (68 to 86°F)

Note

Do not heat the vehicle body or front door rear window frame moulding excessively.

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.

Clean the front door rear window frame moulding (if reusing the front door rear window frame moulding).

Using a heat light, heat the front door rear window frame moulding.
Remove the double-sided tape from the front door rear window frame moulding.
Wipe off any tape adhesive residue with cleaner.

Text in Illustration
*1	Double-sided Tape (A)
*2	Double-sided Tape (B)
*3	Double-sided Tape (C)

Apply new double-sided tape to the front door rear window frame moulding.

Item	Dimension
A	0.8 mm (0.0315 in.)
B	5.0 mm (0.197 in.)
C	13.0 mm (0.512 in.)
D	35.0 mm (1.37 in.)
E	420.0 mm (1.38 ft.)
F	410.0 mm (1.35 ft.)
G	1.2 mm (0.0472 in.)

Text in Illustration

*1 Double-sided Tape

Install the front door rear window frame moulding.
1. Using a heat light, heat the vehicle body and front door rear window frame moulding.
2. Remove the release paper from the face of the front door rear window frame moulding.
  
  Tech Tips
  
  After removing the release paper, keep the exposed adhesive free from foreign matter.
3. Install the front door rear window frame moulding with the clip.

INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
1. Engage the 7 claws to install the front door belt moulding assembly.
INSTALL FRONT DOOR PANEL CUSHION
1. Engage the 2 claws and install 2 new front door panel cushions.
INSTALL FRONT DOOR WEATHERSTRIP
1. Engage the 18 clips and install the front door weatherstrip.
INSTALL FRONT DOOR CHECK ASSEMBLY
1. Apply MP grease to the sliding areas of the front door check assembly.
2. Apply adhesive to the threads of the bolt (A).
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
3. Install the front door check assembly with the 3 bolts.
  
  Torque:
  
  (A)
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  (B)
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL FRONT DOOR LOCK OPEN ROD
1. Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.
INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.
2. Engage the door handle nut and claw.
3. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
INSTALL ELECTRICAL KEY WIRE HARNESS (w/ Entry and Start System)
1. Engage the 4 clamps and install the electrical key wire harness.
2. Connect the connector.
INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)
1. Install the front door inside locking cable assembly as shown in the illustration.
INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)
1. Install the front door inside locking cable assembly as shown in the illustration.
INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)
1. Install the front door lock remote control cable assembly as shown in the illustration.
2. Engage the 7 claws as shown in the illustration.
INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)
1. Install the front door lock remote control cable assembly as shown in the illustration.
2. Engage the 7 claws as shown in the illustration.
INSTALL FRONT DOOR LOCK ASSEMBLY (w/o Double Locking System)
Note
- When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
- Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
- Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock assembly.
1. Apply MP grease to the sliding parts of the front door lock assembly.
2. Install a new door lock wiring harness seal to the front door lock assembly.
3. Insert the front door lock open rod to the front door lock assembly.
4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.
5. Using a T30 "TORX" socket wrench, install the front door lock assembly with the 3 screws.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL FRONT DOOR LOCK ASSEMBLY (w/ Double Locking System)
Note
- When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
- Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
- Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock assembly.
1. Apply MP grease to the sliding parts of the front door lock assembly.
2. Install a new door lock wiring harness seal to the front door lock assembly.
3. Insert the front door lock open rod to the front door lock assembly.
4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.
5. Using a T30 "TORX" socket wrench, install the front door lock assembly with the 3 screws.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Engage the 2 claws and install the front door rear outside handle pad.
INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Engage the 3 claws and install the front door front outside handle pad.
INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY
1. Insert the front end of the front door outside handle assembly into the front door outside handle frame.
2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame, then slide the front door outside handle assembly toward the front of the vehicle to install it.
3. Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.
4. w/ entry and start system:
  1. Connect the connector.
  2. Engage the 2 claws.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)
1. Engage the claw and 2 guides, and install the front door outside handle cover to the front door lock cylinder.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
1. Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Install the hole plug.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)
1. Install the front door outside handle cover with lock cylinder assembly.
  
  Tech Tips
  
  Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.
2. Using a T30 "TORX" socket wrench, install the front door lock cylinder with the screw.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
3. Install the hole plug.
INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
1. Install the front door rear lower frame sub-assembly with the bolt as shown in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL FRONT DOOR GLASS RUN
1. Install the front door glass run.

Text in Illustration
*1	Double-sided Tape

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

INSTALL FRONT DOOR STIFFENER CUSHION

When reusing the front door stiffener cushion:

Clean the front door stiffener cushion.
Remove the double-sided tape from the front door stiffener cushion.
Wipe off any tape adhesive residue with cleaner.

Area	Dimension
*1	40.0 mm (1.575 in.)
*2	17.0 mm (0.669 in.)
*3	3.0 mm (0.118 in.)

Apply new double-sided tape to the front door stiffener cushion as shown in the illustration.

Clean the front door panel sub-assembly.
Text in Illustration

*1 Double-sided Tape

Insert the front door stiffener cushion with the 2 bolts.

INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY
Note

The regulator arm must be below the intermediate position when installing the power window regulator motor.
1. Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly 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.
INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY
1. Apply MP grease to the sliding parts of the front door window regulator assembly.
2. Install the temporary bolt to the front door window regulator assembly.
3. Text in Illustration
  
  *1 Temporary Bolt
  
  Temporarily install the front door window regulator assembly.
4. Tighten the temporary bolt and 5 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
5. Connect the connector.
INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
1. Connect the cable to the negative (-) battery terminal.
2. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
  1. w/ Navigation System for HDD:
    
    Note
    
    After the power switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.
3. Disconnect the cable from the negative (-) battery terminal and power window regulator master switch assembly.
4. Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows, in the order shown in the illustration.
5. Install the front door glass sub-assembly with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
6. Install the grommet.
7. Connect the cable to the negative (-) battery terminal.
  
  Note
  
  When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSTALL FRONT DOOR SERVICE HOLE COVER
1. Apply butyl tape to the front door panel.
2. Text in Illustration
  
  *1 Reference Point
  
  Pass the front door lock remote control cable assembly and front door inside locking cable assembly through a new front door service hole cover.
3. Attach the front door service hole cover according to the reference points on the front door panel.
  
  Note
  
  Securely install the front door service hole cover preventing wrinkles and air bubbles.
INSTALL FRONT DOOR TRIM BRACKET
1. Install the front door trim bracket with the 2 screws.

Text in Illustration
*1	Double-sided Tape

Text in Illustration
*1	Temporary Bolt

Text in Illustration
*1	Reference Point

INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

Using an air riveter or a hand riveter, install the front No. 1 speaker assembly with 4 new rivets.

Text in Illustration
*1	Riveter	*2	Mandrel
*a	INCORRECT	-	-

Note

Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
Confirm that the rivet is seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any clearance between the rivet head and moulding.
Do not leave any clearance between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

Tech Tips

If the rivet cannot be cut, pull it once and cut it.

Connect the connector.

INSTALL DOOR FRAME GARNISH
1. Engage the clip to install a new door frame garnish.
INSTALL OUTER REAR VIEW MIRROR ASSEMBLY
1. Engage the clip to install the outer rear view mirror assembly.
2. Install the outer rear view mirror assembly with the 3 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
3. Connect the connector.
INSTALL OUTER MIRROR INSTALL HOLE COVER
1. Engage the guide and 2 claws to install the outer mirror install hole cover.
INSTALL OUTER MIRROR PROTECTOR
1. Engage the 2 claws.
2. Install the outer mirror protector with the screw.
INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP
1. Engage the 7 claws and install the front door inner glass weatherstrip to the front door trim board sub-assembly as shown in the illustration.
INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Connect the front door lock remote control cable assembly and front door inside locking cable assembly to the front door inside handle.
2. Engage the 2 claws and install the front door inside handle sub-assembly to the front door trim board sub-assembly.
INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY
1. Engage the 9 clips and install the front door trim board sub-assembly.
2. Install the 2 screws.
3. Remove the 2 pieces of protective tape.
INSTALL COURTESY LIGHT ASSEMBLY
1. Connect the connector.
2. Engage the claw to install the courtesy light assembly.
INSTALL DOOR ARMREST COVER
1. Install the door armrest cover.
INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)
1. Connect the connector.
2. Engage the 7 claws and 3 guides, and install the power window regulator master switch assembly with front door armrest base panel.
INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)
1. Connect the connector.
2. Engage the 7 claws and 3 guides, and install the power window regulator switch assembly with front door armrest base panel.
INSTALL ASSIST GRIP COVER
1. Engage the 6 claws, 2 clips and 3 guides, and install the assist grip cover.
INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG
1. Engage the 3 claws and install the front door inside handle bezel plug.
INITIALIZE POWER WINDOW CONTROL SYSTEM

Click here
INSTALL REAR NO. 3 FLOOR BOARD
1. Engage the 2 guides to install the rear No. 3 floor board.
INSTALL REAR DECK FLOOR BOX
1. Install the rear deck floor box.
INSTALL REAR NO. 2 FLOOR BOARD
1. Engage the 3 guides <A>.
2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.