FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RHD and LHD vehicle.

  • The procedure listed below is for the LHD vehicle.

PROCEDURE


  1. INSTALL NO. 2 BLACK OUT TAPE

    Click here

  2. INSTALL NO. 1 BLACK OUT TAPE

    Click here

  3. INSTALL FRONT DOOR PANEL CUSHION


    1. A005J0D

      Install the new 2 front door panel cushions.

  4. INSTALL FRONT DOOR WEATHERSTRIP


    1. A005GQ8E01

      Engage the 15 clips.

    2. Engage the clip (A) and the clip (B) and install the front door weatherstrip.

  5. INSTALL DOOR FRAME GARNISH


    1. A005KXZ

      Engage the claw to install a new door frame garnish.

  6. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A005IB1E02
      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


    1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.

    2. A005HQRE01

      Attach 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 3 claws.

      Text in Illustration
      *1 Grommet
    4. A005IUC

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

    5. A005MDG

      Engage the clamp (w/ Entry and Start System).

  8. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD


    1. A005IR6

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

  9. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD


    1. A005IZV

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

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


    1. A005KFE

      Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.

    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame sub-assembly, then slide the front door outside handle assembly toward the front of the vehicle and install it.

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


    1. A005ICM

      Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.

    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame sub-assembly, then slide the front door outside handle assembly toward the front of the vehicle and install it.

    3. A005I9R

      Connect the connector.

    4. Engage the 3 claws.

    5. A005HVA

      Engage the 2 clamps.

  12. INSTALL FRONT DOOR LOCK ASSEMBLY

    Click here

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


    1. A005M5I

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

    2. Temporarily install the front door outside handle cover.

    3. A005I8I

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

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


    1. A005LLX

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

  15. INSTALL HOLE PLUG (for Rear Side)


    1. A005KRZ

      Install the hole plug.

  16. INSTALL HOLE PLUG (for Front Side)


    1. A005IL6

      Install the hole plug.

  17. INSTALL FRONT DOOR CHECK ASSEMBLY

    A005KKDE02

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

  18. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  19. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Click here

  20. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

    Click here

  21. INSTALL OUTER MIRROR INSTALL HOLE COVER

    Click here

  22. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. Engage the guide.

    2. A005LSK

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

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

  23. INSTALL FRONT DOOR GLASS RUN


    1. A005HLD

      Install the front door glass run.

  24. INSTALL NO. 1 FRONT DOOR STIFFENER CUSHION


    1. Clean the front door panel surface.


      1. Remove the double-sided tape from the front door panel.

      2. Wipe off any tape adhesive residue with cleaner.

    2. Remove the peeling paper from the face of the No. 1 front door stiffener cushion.

      Tech Tips

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

    3. A005KF1

      Install the No. 1 front door stiffener cushion with the 2 bolts.

      Torque:
      6.2 N*m  { 63 kgf*cm, 55 in.*lbf }
      Text in illustration
      A005H6N Double-sided Tape

  25. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY


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

    2. A005LUXE01
      Text in illustration
      *1 Temporarily Bolt

      Install the temporarily bolt.

    3. Tighten the 5 bolts and the temporarily bolt to install the front door window regulator sub-assembly.

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

    4. Connect the connector.

  26. 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 bolt holes can be seen.

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

    4. A005I1CE01

      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 as shown in the illustration.

      Note

      Do not damage the front door glass.

    5. A005K8B

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

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

  27. 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. A005M6ME01
      Text in Illustration
      *1 Reference Point

      Install a new 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.

    4. Connect the connector.

  28. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  29. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (for 6 Speakers)

    Click here

  30. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP


    1. A005LF7

      Engage the 7 claws and install the front door glass inner weatherstrip to the front door trim board sub-assembly as shown in the illustration.

  31. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A005HWH

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

  32. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. Connect the front No. 2 speaker connector (for 6 Speakers).

    2. A005KSGE02
      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 sub-assembly.

    3. Attach the upper section of the front door trim board sub-assembly to the front door panel.

    4. A005LY0

      Engage the 8 clips.

    5. A005MG8

      Install the 2 screws and the front door trim board sub-assembly.

    6. A005M6YE02
      Text in illustration
      *1 Cover

      Install the screw and close the cover.

  33. INSTALL FRONT UPPER ARMREST BASE PANEL


    1. Connect the connector.

    2. A005GVP

      Engage the 2 clips and 9 claws, and install the front upper armrest base panel to the front door trim board sub-assembly.

  34. CONNECT CABLE TO NEGATIVE 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.

  35. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here