FRONT DOOR REASSEMBLY


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING


    1. A003WKU

      Engage the front door upper window frame moulding to the door frame.

    2. Using an air riveter or hand riveter with a nose piece, install the front door upper window frame moulding with 8 new rivets.

      Tech Tips

      If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

      Note


      • A003YE3E09

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

        Text in Illustration
        *1 Riveter
        *2 Mandrel
        *a Incorrect
      • A003ZTQE10

        Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding.

        Text in Illustration
        *1 Riveter
        *a Incorrect
      • A003XD6E12

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

        Text in Illustration
        *1 Riveter
        *a Incorrect

  3. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Tech Tips

    When installing a new 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.


    1. 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.

    2. A003YIKE01
      Text in Illustration
      *1 Double-sided Tape
      *2 Caulking Sponge

      Install a new 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.

  4. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY


    1. A003YRP

      Engage the 7 claws to install the front door belt moulding assembly.

  5. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

    Tech Tips

    When installing a new front door front lower frame upper cover, heat the vehicle body using a heat light.

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

    Note

    Do not heat the vehicle body or moulding excessively.


    1. 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.

    2. Install a new front door front lower frame upper cover.


      1. Using a heat light, heat the vehicle body and a new front door front lower frame upper cover.

      2. Remove the release paper from the front door front lower frame upper cover.

        Tech Tips

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

      3. Engage the 2 clips and install the new front door front lower frame upper cover.

  6. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


      1. 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.

      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 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 elasticity increases.

    3. 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.

    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 flat.

        Note

        Do not bend the tape or leave it in high temperature places.

    5. 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.

        A003X7RE02
        Text in Illustration
        *A Pressing Forward *B Pulling
        *1 Non-padded Side *2 Padded Side
        *3 Squeegee *4 Black Out Tape
        *5 Release Paper - -
        *a Side View - -
        Reference Measurement
        Area Measurement
        A 10 to 20 mm (0.393 to 0.787 in.)
        B 30 to 70 mm (1.18 to 2.76 in.)
        C 40 to 50° (for pressing forward)
        D 30 to 45° (for pulling)

        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.

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


      1. A003XUCE09
        Text in Illustration
        *1 Squeegee
        *2 Hem
        *a First
        *b Second
        *c Third

        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.

    7. 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.

    8. 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.

  7. INSTALL FRONT DOOR REAR OUTSIDE STRIPE


    1. Refer to the illustration to position the front door rear outside stripe.

      A003X4FE01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Square
      *c Round - -
      Standard Measurement
      Dimension Measurement
      A 1.5 mm (0.0591 in.)
      B 1.0 mm (0.0394 in.)

    2. Remove the release paper and apply the stripe.

  8. INSTALL FRONT DOOR OUTSIDE STRIPE


    1. Refer to the illustration to position a new front door outside stripe.

      A003XQ8E01
      Text in Illustration
      *A LH Side *B RH Side
      *a Edge of Curved Surface *b Square
      *c Round - -
      Standard Measurement
      Dimension Measurement
      A 1.5 mm (0.0591 in.)
      B 1.0 mm (0.0394 in.)

    2. Remove the release paper and apply the stripe.

  9. INSTALL DOOR DUST PROOF SEAL


    1. A003VP0

      Install door dust proof seal.

  10. INSTALL FRONT DOOR PANEL CUSHION


    1. A003VZ4

      Engage the 2 claws to install 2 new front door panel cushions.

  11. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP


    1. A003XXY

      Engage the 8 clips to install the front door No. 2 weatherstrip.

  12. INSTALL FRONT DOOR WEATHERSTRIP


    1. A003WW1E01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 20 clips and install a new front door weatherstrip.

  13. 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.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A003WJO

      Install the front door check assembly with the bolt and 2 nuts.

      Torque:
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  14. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A003YCPE01

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

  15. 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. A003WZR

      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 }

  16. INSTALL FRONT DOOR WIRE


    1. A003VW5

      Engage the 5 clamps and install the electrical key wire harness.

    2. Connect the connector.

  17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A003ZNR

      Install the front door inside locking cable assembly.

    2. A003WQ9

      Engage the 3 claws.

  18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A003ZJV

      Install the front door lock remote control cable assembly.

  19. INSTALL FRONT DOOR LOCK ASSEMBLY

    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. A003ZDU

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

    3. A003V8TE01
      Text in Illustration
      *1 Front Door Lock Open Rod

      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 }

    6. Connect the connector.

  20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A003X9S

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

  21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A003XWT

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

  22. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A003W4Y

      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. A003Y8Y

      Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

    4. A003V7H

      Connect the connector.

    5. Engage the 2 claws.

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


    1. A003YJW

      Engage the claw and 2 guides, and install the front door outside handle cover to the front door lock cylinder as shown in the illustration.

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


    1. A003Y2T

      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. A003XMC

      Install the hole plug.

  25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)


    1. A003WB6

      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. A003WI2

      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. A003V51

      Install the hole plug.

  26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A003XE1

      Engage the guide.

    2. Install the front door rear lower frame sub-assembly with the bolt as shown in the illustration.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  27. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION


    1. When reusing the No. 2 front door stiffener cushion:


      1. Clean the No. 2 front door stiffener cushion.

      2. Remove the double-sided tape from the No. 2 front door stiffener cushion.

      3. Wipe off any tape adhesive residue with cleaner.

      4. A003WL7E01

        Apply new double-sided tape to the No. 2 front door stiffener cushion as shown in the illustration.

        Area Dimension
        (A) 80.0 mm (3.150 in.)
        (B) 20.0 mm (0.787 in.)
        (C) 4.0 mm (0.157 in.)

    2. Clean the front door panel sub-assembly.

    3. A003X95E01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 2 guides.

    4. Install the front door stiffener cushion with the 2 bolts.

  28. INSTALL FRONT DOOR GLASS RUN


    1. A003WDM

      Install the front door glass run.

  29. 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. A003X17

      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.

  30. 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. A003ZJDE02
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the front door window regulator assembly.

    4. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly.

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

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

    5. Connect the connector.

  31. 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.

    3. 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.

    4. Disconnect the power window regulator master switch assembly.

    5. A003WTFE01

      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.

    6. A003ZONE01

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

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    7. A003W2Q

      Install the grommet.

  32. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the front door panel.

    2. A003VIHE01
      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.

  33. INSTALL FRONT DOOR TRIM BRACKET (for Driver Side)


    1. A003XFU

      Install the front door trim bracket with the 2 screws.

  34. INSTALL FRONT DOOR TRIM BRACKET (for Front Passenger Side)


    1. A003XK4

      Install the front door trim bracket with the 2 screws.

  35. INSTALL WIRING HARNESS CLAMP BRACKET (w/o Memory)


    1. A003X44

      Install the wiring harness clamp bracket with the 2 screws.

    2. Engage the clamp.

  36. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY


    1. Engage the claw to temporarily install the outer rear view mirror assembly.

    2. Install the outer rear view mirror assembly with the 3 nuts.

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

    3. w/o Memory:


      1. Engage the clamp.

    4. w/ Memory:


      1. Engage the clamp.

        Tech Tips

        Align the marking on the wire harness with the clamp, and then engage the clamp.

    5. Connect the connector.

  37. INSTALL OUTER MIRROR PROTECTOR


    1. A003YB4E01
      Text in Illustration
      *1 Reference Point

      Attach a new outer mirror protector according to the reference points on the front door panel.

      Note

      Securely install the outer mirror protector preventing wrinkles and air bubbles.

  38. INSTALL OUTER MIRROR INSTALL HOLE COVER


    1. Engage the clamp.

      Tech Tips

      Align the marking on the wire harness with the clamp, and then engage the clamp.

    2. Engage the 2 claws.

    3. Install the outer mirror install hole cover with the bolt.

  39. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)


    1. Install the outer mirror control ECU assembly with the 2 screws.

    2. Connect each connector.

  40. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


    1. A003X97E01

      Install the front No. 1 speaker assembly with the 4 bolts.

      Note

      Do not touch the speaker cone.

      Tech Tips

      Install the bolts in the order shown in the illustration.

    2. Connect the connector.

  41. INSTALL DOOR FRAME GARNISH


    1. A003VE8

      Engage the clip to install a new door frame garnish.

  42. INSTALL FRONT DOOR TRIM SEAL


    1. A003Y4H

      Engage the 8 clips to install the front door trim seal.

  43. INSTALL FRONT DOOR WIRING SUB-ASSEMBLY (w/ Seat Position Memory System)


    1. A003WUD

      Engage the 3 clamps and install the front door wiring sub-assembly.

  44. INSTALL SEAT MEMORY SWITCH (w/ Seat Position Memory System)


    1. Engage the 4 claws to install the seat memory switch.

    2. Connect the connector.

  45. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A003W69

      Engage the 8 claws to install the front door inner glass weatherstrip as shown in the illustration.

  46. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A003X1W

      Engage the claw and 2 guides, and install the front door inside handle sub-assembly to the front door trim board sub-assembly as shown in the illustration.

  47. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for Driver Side)


    1. A003VEHE01
      Text in Illustration
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly

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

    2. w/ Seat Position Memory System:


      1. Connect the connector.

    3. A003Z92

      Engage the 11 clips and install the front door trim board sub-assembly.

    4. Install the 2 screws.

    5. Remove the protective tape.

  48. INSTALL DOOR ARMREST COVER (for Driver Side)


    1. A003W2R

      Install the door armrest cover.

  49. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)


    1. Connect the connector.

    2. A003VBU

      Engage the 2 guides, 3 clips and 7 claws, and install the power window regulator master switch assembly with front door armrest base panel.

  50. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for Front Passenger Side)


    1. A003VRFE01
      Text in Illustration
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly

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

    2. A003WPQ

      Engage the 11 clips and install the front door trim board sub-assembly.

    3. Install the 3 screws.

    4. Remove the protective tape.

  51. INSTALL DOOR ASSIST GRIP ASSEMBLY (for Front Passenger Side)


    1. A003VKE

      Engage the 3 guides and install the door assist grip assembly.

    2. Install the 2 screws.

  52. INSTALL DOOR ASSIST GRIP COVER (for Front Passenger Side)


    1. A003WHG

      Engage the guide and 4 claws to install a new door assist grip cover.

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


    1. Connect the connector.

    2. A003ZG0

      Engage the 4 guides, 3 clips and 8 claws, and install the power window regulator switch assembly with front door armrest base panel.

  54. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. A003XX5

      Engage the clip and claws, and install the front door lower frame bracket garnish.

  55. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A003Y8Q

      Engage the 3 claws and install the front door inside handle bezel plug.

  56. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  57. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.

  58. INSTALL DECK FLOOR BOX RH


    1. Engage the 6 guides.

    2. Install the deck floor box RH with the clip.

  59. INSTALL REAR NO. 3 FLOOR BOARD


    1. Install the rear No. 3 floor board.

  60. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  61. INSTALL REAR NO. 2 FLOOR BOARD


    1. Install the rear No. 2 floor board.

  62. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here