FRONT DOOR REASSEMBLY

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 NO. 3 WEATHERSTRIP LH


    1. Install the front door No. 3 weatherstrip with 4 new clips.

    2. Install the front door panel with the 4 bolts.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      CAUTION:

      Be sure to perform this procedure with 2 or more persons as the part is very heavy.

    3. Connect the front door wire to the front door panel with the 2 bolts.

    4. Attach the 8 clamps of the front door wire.

  2. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH


    1. Attach the claw and clip to install the front door outside moulding.

    2. Install a nose piece to an air riveter or hand riveter.

    3. Insert the mandrel part of a new rivet into the nose piece.

    4. Place the riveter upright against the front door outside moulding and install the 7 rivets.

      Tech Tips

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

      Note


      • A01FU18E15

        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
        *b CORRECT
      • A01FS5BE17

        Confirm that the rivets are seated properly against the front door outside moulding.

      • Do not tilt the riveter when installing the rivet to the front door outside moulding.

      • Do not leave any space between the rivet head and front door outside moulding.

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT
      • A01FSKYE15

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

        Text in Illustration
        *1 Riveter
        *a INCORRECT
        *b CORRECT
      A01FVQ3

  3. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER LH


    1. Install the front door lower frame upper cover with the nut.

  4. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Tech Tips

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

    Standard
    Item Temperature
    Front Door Panel 40 to 60°C (104 to 140°F)
    Front Door Rear Window Frame Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the front door panel or front door rear window frame moulding 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. A01FS0NE01
      Text in Illustration
      *1 Double-sided Tape
      *2 Butyl Tape

      Install a new front door rear window frame moulding.


      1. Using a heat light, heat a new front door rear window frame moulding and the front door panel surface.

      2. Remove the peeling paper from the face of the front door rear window frame moulding.

        Tech Tips

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

      3. Attach the clip and guide to install the front door rear window frame moulding.

        Tech Tips

        Press the front door rear window frame moulding firmly to install it.

  5. INSTALL FRONT DOOR REAR BELT MOULDING END COVER LH

    Tech Tips

    When installing the front door rear belt moulding end cover, heat the front door panel and front door rear belt moulding end cover using a heat light.

    Standard
    Item Temperature
    Front Door Panel 40 to 60°C (104 to 140°F)
    Front Door Rear Belt Moulding End Cover 20 to 30°C (68 to 86°F)

    Note

    Do not heat the front door panel or front door rear belt moulding end cover 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. A01FSVUE01
      Text in Illustration
      *1 Double-sided Tape

      Install a new front door rear belt moulding end cover.


      1. Using a heat light, heat a new front door rear belt moulding end cover and the front door panel surface.

      2. Remove the peeling paper from the face of the front door rear belt moulding end cover.

        Tech Tips

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

      3. Attach the 2 clips to install the front door rear belt moulding end cover.

        Tech Tips

        Press the front door rear belt moulding end cover firmly to install it.

  6. INSTALL FRONT DOOR WEATHERSTRIP LH


    1. Attach the 17 clips to install the front door weatherstrip.

  7. INSTALL FRONT DOOR CHECK ASSEMBLY LH


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

    2. When reusing a bolt:


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

      2. Apply adhesive to the threads of the bolt.

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

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

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

  8. INSTALL FRONT DOOR DUST PROOF SEAL

    Tech Tips

    Use the same procedure for all front door dust proof seals.


    1. Attach the claw to install a front door dust proof seal.

  9. INSTALL FRONT DOOR PANEL CUSHION


    1. Install a new front door panel cushion.

  10. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH


    1. Attach the 9 clips to install the front door No. 2 weatherstrip.

  11. INSTALL FRONT DOOR LOCK OPEN ROD LH


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

    2. A01FUM2E01
      Text in Illustration
      *1 Snap

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

  12. 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 2 clamps of the front door wire to the front door outside handle frame.

    3. 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 }

  13. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


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

  14. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. Attach the 3 claws to install the front door front outside handle pad.

  15. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH


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

    2. A01FVM0

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

    3. A01FT8RE01
      Text in Illustration
      *1 Holder

      Attach the holder in the direction indicated by the arrow in the illustration.

    4. Attach the claw of the connector to connect the connector.

    5. Attach the 2 claws of the connector cover to connect the connector cover.

  16. 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.

  17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH


    1. Install the front door lock remote control cable.

  18. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    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. A01FRRFE01
      Text in Illustration
      *A w/o Double Locking System
      *B w/ Double Locking System

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

    6. Connect the connector.

  19. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY


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

  20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH


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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install the hole plug.

  21. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

    Tech Tips

    When installing the front door No. 2 stiffener cushion, 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.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new front door No. 2 stiffener cushion.


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

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

        Tech Tips

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

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

        Tech Tips

        Press the front door No. 2 stiffener cushion firmly to install it.

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


    1. Attach the guide to install the front door rear lower frame.

    2. Install the 2 bolts.

  23. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH


    1. Attach the 2 claws and temporarily install the outer rear view mirror assembly LH.

    2. Install the outer rear view mirror assembly LH with the 3 bolts.

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

    3. Attach the 2 clamps.

    4. Connect the connector.

  24. INSTALL OUTER MIRROR PROTECTOR


    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. A01FTYUE01
      Text in Illustration
      *a Reference Point

      Install a new outer mirror protector.


      1. Remove the peeling paper from the face of the outer mirror protector.

        Tech Tips

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

      2. Install the outer mirror protector using the reference points on the front door panel.

        Tech Tips


        • Press the outer mirror protector firmly to install it.

        • Securely install the outer mirror protector to prevent wrinkles and air bubbles.

        • There should be no wrinkles or folds after installing the outer mirror protector.

        • After installing the outer mirror protector, check the seal quality.

  25. INSTALL FRONT MULTIPLEX NETWORK DOOR ECU LH


    1. Install the front multiplex network door ECU with the 2 bolts.

    2. Connect the 3 connectors.

  26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH


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

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

    3. A01FSARE01
      Text in Illustration
      *1 Temporary Bolt

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

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

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

    4. Connect the connector.

  27. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH


    1. Attach the 5 claws to install the front door belt moulding.

  28. INSTALL FRONT DOOR GLASS RUN LH


    1. Install the front door glass run.

  29. 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 (-) auxiliary 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 (-) auxiliary 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. A01FV93E01

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

  30. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


    1. Connect the speaker connector.

      A01FTLTE02
      Text in Illustration
      *A w/o Mark Levinson Speaker System *B w/o Mark Levinson Speaker System

    2. Temporarily install the speaker by attaching the claw of the speaker to the door panel.

    3. Install the front No. 1 speaker assembly with the 4 screws.

      Note

      Do not touch the cone of the speaker.

      Tech Tips

      Tighten the screws in the order shown in the illustration.

  31. INSTALL FRONT DOOR NO. 2 SERVICE HOLE COVER LH


    1. A01FTXFE01
      Text in Illustration
      *a Reference Point

      Install a new front door No. 2 service hole cover using the reference points on the front door panel.

      Tech Tips


      • Securely install the front door No. 2 service hole cover to prevent wrinkles and air bubbles.

      • There should be no wrinkles or folds after installing the front door No. 2 service hole cover.

      • After installing the front door No. 2 service hole cover, check the seal quality.

  32. INSTALL FRONT DOOR SERVICE HOLE COVER LH


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

    2. A01FV78E01
      Text in Illustration
      *a Reference Point

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

      Tech Tips


      • Securely install the front door service hole cover to prevent wrinkles and air bubbles.

      • There should be no wrinkles or folds after installing the front door service hole cover.

      • After installing the front door service hole cover, check the seal quality.

  33. INSTALL FRONT DOOR ARMREST SET BRACKET LH


    1. Install the front door armrest set bracket with the 2 screws.

  34. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH


    1. Install the front door inner glass weatherstrip.

  35. INSTALL DOOR FRAME GARNISH LH


    1. Attach the 2 clips to install the door frame garnish.

  36. INSTALL FRONT DOOR TRIM COVER LH


    1. Attach the 5 clips to install the front door trim cover.

  37. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION


    1. Install the front door No. 1 stiffener cushion.

  38. INSTALL FRONT DOOR TRIM SEAL LH


    1. Attach the 11 clips to install the front door trim seal.

  39. INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY LH


    1. Attach the 3 claws to install the front door trim ornament to the No. 1 interior illumination light.

  40. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH


    1. Attach the claw to install the front door inside handle.

    2. Install the screw.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Install the front door inside handle together with the front door trim ornament and No. 1 interior illumination light with the 15 screws.

  41. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH


    1. Connect the connector.

    2. Attach the 2 claws to install the front door inside handle illumination light assembly LH.

  42. INSTALL SEAT MEMORY SWITCH


    1. Install the seat memory switch to the front door trim board sub-assembly with the 2 screws.

  43. INSTALL SWITCH BEZEL

    A01FQD5

    1. Attach the 4 claws to install the switch bezel to the seat memory switch.

  44. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH


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

    2. Connect each connector.

    3. A01FVSRE01
      Text in Illustration
      *1 Reference Boss

      Attach the 4 claws to install the front door trim board to the front door inner glass weatherstrip.

    4. Attach the reference boss in the direction indicated by the arrow in the illustration.

    5. Attach the 9 clips to install the front door trim board.

    6. Install the 3 screws.

  45. INSTALL FRONT DOOR HOLE COVER


    1. Install the front door hole cover.

  46. INSTALL COURTESY LIGHT ASSEMBLY


    1. Connect the connector.

    2. Attach the claw to install the courtesy light assembly.

  47. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH


    1. Attach the 3 claws to install the front door inside handle bezel plug.

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


    1. Connect the connector.

    2. Attach the 5 claws and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.

  49. ADJUST FRONT DOOR PANEL SUB-ASSEMBLY LH

    Click here

  50. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  51. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  52. CHECK POWER WINDOW CONTROL SYSTEM

    Click here

  53. CHECK POWER DOOR LOCK CONTROL SYSTEM

    Click here

  54. CHECK OUTER REAR VIEW MIRROR

    Click here

  55. CHECK SEAT MEMORY SWITCH


    1. for LHD:

      Click here

    2. for RHD:

      Click here

  56. CHECK SRS WARNING LIGHT

    Click here