FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. INSTALL FRONT DOOR HOLE COVER


    1. A004H96

      Insert the front door hole cover with the 4 claws.

  2. INSTALL DOOR SIDE AIR BAG SENSOR

    Click here

  3. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Click here

  4. INSTALL FRONT DOOR PANEL CUSHION


    1. A004K6W

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

  5. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. A004K9G

      Apply adhesive to the threads of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Install the bolt.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

    4. Install the front door check assembly with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  6. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A004IOYE01

      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. A004J0XE01
      Text in Illustration
      *a Outside Vehicle
      *b Inside Vehicle

      Engage the claw.

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  8. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A004HLI

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

  9. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A004K9T

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

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


    1. A004JNI

      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, and then slide the front door outside handle assembly toward the front of the vehicle to install it.

    3. A004HOL

      Connect the connector.

    4. Engage the 3 claws.

    5. A004IDY

      Engage the clamp.

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


    1. A004JNI

      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, and then slide the front door outside handle assembly toward the front of the vehicle to install it.

  12. INSTALL FRONT DOOR LOCK ASSEMBLY

    Click here

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


    1. A004HVN

      Engage the claw and 2 guides, and install the front door outside handle cover to the front door lock cylinder assembly.

  14. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)


    1. A004ITU

      Install the front door outside handle cover with front door lock cylinder assembly.

      Tech Tips

      Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

    2. A004J0S

      Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly with the screw.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

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


    1. A004I9K

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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  16. INSTALL FRONT DOOR WEATHERSTRIP


    1. Engage the 16 clips.

    2. Engage the claw.

    3. Install the front door weatherstrip with the screw.

      A004HPQ

  17. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Click here

  18. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY


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

    2. Install the temporary bolt to the front door window regulator sub-assembly.

    3. A004HRPE01
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the front door window regulator sub-assembly.

    4. Tighten the 3 bolts and 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    5. Tighten the temporary bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    6. Connect the connector.

  19. INSTALL FRONT DOOR SASH STOPPER


    1. Install the front door sush stopper with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  20. INSTALL FRONT DOOR SUSH


    1. A004K4TE01

      Insert the front door sush so that it is perpendicular to the front door frame, in the order shown in the illustration.

    2. Rotate the front door sush 90°.

      Note

      Do not damage the front door sush.

    3. A004KUCE03

      Install the front door sush with the 3 nuts.

      Torque:
      Nut(A)
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
      Torque:
      Nut(B)
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  21. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the power window regulator master switch assembly connector (for driver side).

    3. Connect the power window regulator switch assembly connector (for front passenger side).

    4. Move the front door glass sub-assembly until the 2 nuts can be seen through the service holes.

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

    6. Disconnect the power window regulator master switch assembly connector (for driver side).

    7. Disconnect the power window regulator switch assembly connector (for front passenger side).

    8. A004KCU

      Insert the front door glass sub-assembly into the front door frame from the position indicated in the illustration.

      Note

      Do not damage the front door weatherstrip.

      Tech Tips

      The front door glass sub-assembly can only be installed from the position indicated in the illustration, so install it while sliding the front door rear lower frame sub-assembly.

    9. Insert the grommet of front door glass assembly into the rail of the front door rear lower frame sub-assembly.

    10. A004JCVE03
      Text in Illustration
      *1 Nut A
      *2 Nut B
      *3 Front Door Glass Sub-assembly
      *4 Front Door Window Regulator Sub-assembly
      *5 Bolt
      *a SST Number

      Install a new nut B temporarily to the front door glass sub-assembly.

    11. Install SST as shown in the illustration.

      SST
      09801-18010

      Tech Tips

      The SST number on SST must be visible.

    12. Secure the bolt using SST, and then tighten a new nut A to the specified torque.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    13. Tighten nut B to the specified torque.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  22. INSTALL DOOR GLASS INNER STABILIZER


    1. Install the door glass inner stabilizer with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  23. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. Install the front door rear lower frame sub-assembly with the 3 nuts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  24. INSTALL OUTER REAR VIEW MIRROR SUB-ASSEMBLY

    Click here

  25. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY


    1. Check the front door glass sub-assembly Click here.

    2. Adjust the front door glass sub-assembly Click here.

  26. 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 and the front door inside locking cable assembly through a new front door service hole cover.

      A004JBGE01
      Text in Illustration
      *1 Reference Point - -

    3. Attach the front door service hole cover according to the reference points on the front door panel.

      Note


      • Overlay the butyl tape in lengths of 20 cm (7.874 in.) or more.

      • Do not block the drip holes in the front door panel with butyl tape.

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

    4. Connect each connector.

  27. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (w/ Front Speaker)

    Click here

  28. INSTALL FRONT DOOR SPEAKER HOLE COVER (w/o Front Speaker)


    1. A004KKK

      Install the front door speaker hole cover with the 3 screws.

  29. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP


    1. A004JF0

      Engage the 9 claws to install a new front door glass inner weatherstrip to the front door trim board sub-assembly as shown in the illustration.

    2. A004JQO

      Install a nose piece to an air riveter, and then insert the mandrel part of a new rivet into the nose piece.

    3. Hold the riveter perpendicular against the moulding and install the 6 rivets.

      Tech Tips

      If the rivet cannot be cut, pull it once again to cut it. Also, be sure to cut off the head.

      Note


      • A004HEXE63

        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
      • A004KXBE42

        Confirm that the rivets are seated properly against the front door glass inner weatherstrip.

        Text in Illustration
        *1 Riveter
        *a Incorrect
        *b Correct

      • Do not tilt the riveter when installing the rivet to the front door glass inner weatherstrip

      • Do not leave any space between the rivet head and front door glass inner weatherstrip.

    4. A004JK6E02
      Text in Illustration
      *1 Front Door Glass Sub-assembly
      *2 Front Door Trim Board Sub-assembly
      *3 Nonwoven Tape
      *4 Rivet
      *5 Front Door Glass Inner Weatherstrip

      After installing the rivet, cut nonwoven tape into a 15 mm (0.591 in.) x 15 mm (0.591 in.) square and attach it to the crimped section of the rivet.

      Note


      • The crimp height of the rivet must be 3 mm (0.118 in.).

      • If the crimp is not firm enough, flatten it using pliers or the like to avoid interference with the door panel.

    5. After installing the front door glass inner weatherstrip, check the following items:


      • Check that there is no gap between the front door glass inner weatherstrip and the front door trim board sub-assembly.

      • Pull the front door glass inner weatherstrip lightly and check that there is no play.

  30. INSTALL FRONT LOWER DOOR TRIM PAD


    1. A004IRU

      Install the front lower door trim pad with the 5 screws.

  31. INSTALL DOOR ASSIST GRIP ASSEMBLY


    1. A004KDX

      Engage the guide and install the door assist grip assembly with the 2 screws.

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


    1. A004KXN

      Install the power window regulator master switch assembly with front door armrest base panel with the 4 screws.

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


    1. A004IGS

      Install the power window regulator switch assembly with front door armrest base panel with the 4 screws.

  34. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A004H1H

      Engage the 2 guides.

    2. Install the front door inside handle sub-assembly to the front door trim board sub-assembly with the 2 screws.

  35. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A004KX6E01
      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 to the front door inside handle.

    2. Connect each connector.

    3. A004JGU

      Engage the 10 clips and install the front door trim board sub-assembly.

    4. A004IUU

      Engage the clip and install the 3 screws.

    5. A004KNA

      Engage the claw and install the cap.

  36. INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)

    Click here

  37. INSTALL DOOR ARMREST COVER


    1. A004K3N

      Engage the guide and 7 claws, and install the door armrest cover.

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  39. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  40. INSPECT POWER WINDOW

    Click here