FRONT DOOR REASSEMBLY


  1. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING


    1. Clean the vehicle body surface.


      1. Remove any caulking sponge from the vehicle body.

      2. Wipe off any tape adhesive residue with cleaner.

    2. A019O0CE01
      Text in Illustration
      *1 Caulking Sponge

      Install a new front door front window frame moulding.


      1. Remove the release paper from the face of the front door front window frame moulding.

        Tech Tips

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

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

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

        Tech Tips

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

        Note

        A019K7CE01

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

        • A019K1KE01

          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.

        • A019LDAE09

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

  2. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING


    1. A019NPT

      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 6 new rivets.

      Tech Tips

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

      Note

      A019K7CE01

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

      • A019K1KE01

        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.

      • A019LDAE08

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

  3. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY


    1. A019OPME01

      Install the front door panel sub-assembly with the 4 bolts <B>.

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

      Note

      To prevent damage, when installing the front door panel sub-assembly, make sure that there are enough people available to hold it securely.

    2. Apply adhesive to the threads of the bolt <A>.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Engage the front door check assembly with the bolt <A>.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    4. A019LVRE01

      Using a brush, apply anti-rust coating to the front door hinge assembly as shown in the illustration.

    5. Connect each connector.

    6. Engage each clamp.

  4. INSTALL COWL SIDE TRIM SUB-ASSEMBLY


    1. A019L27

      Engage the 2 clips to install the cowl side trim sub-assembly LH.

    2. Install the clip.

  5. INSTALL FRONT DOOR SCUFF PLATE


    1. w/ Illumination:


      1. Connect the connector.

    2. A019LA0

      Engage the 4 clips, guide and 7 claws, and install the front door scuff plate LH.

  6. 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.


    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. A019LP6E01
      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.

  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY


    1. A019P0H

      Engage the 6 claws to install the front door belt moulding assembly.

  8. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

    Tech Tips

    When installing the front door outside moulding sub-assembly, heat the vehicle body and front door outside moulding sub-assembly 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)

    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. A019KCEE01

      Clean the front door outside moulding sub-assembly.

      Standard Measurement
      Dimension Measurement
      A 1.2 mm (0.0472 in.)
      B 10.0 mm (0.394 in.)

      1. Using a heat light, heat the front door outside moulding sub-assembly.

      2. Remove the double-sided tape from the front door outside moulding sub-assembly.

      3. Wipe off any tape adhesive residue with cleaner.

      4. Apply new double-sided tape to the front door outside moulding sub-assembly.

    3. Install 10 new clips (quarter vent louver retainer) to the front door outside moulding sub-assembly.

    4. Install the bolt to the front door outside moulding sub-assembly.

    5. Install a new gasket to the bolt.

    6. A019KD4E01
      Text in Illustration
      *1 Double-sided Tape

      Install the front door outside moulding sub-assembly.


      1. Using a heat light, heat the vehicle body and front door outside moulding sub-assembly.

      2. Remove the release paper from the front door outside moulding sub-assembly.

        Tech Tips

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

      3. Engage the 10 clips and guide to install the front door outside moulding sub-assembly.

    7. A019KL7

      Install the nut and hole plug.

  9. INSTALL FRONT DOOR LOWER OUTSIDE MOULDING


    1. Install 5 new clips (quarter vent louver retainer) to the front door lower outside moulding.

    2. A019LYT

      Engage the 5 clips and 5 claws to install the front door lower outside moulding.

  10. INSTALL FRONT DOOR WEATHERSTRIP


    1. A019MK0E01
      Text in Illustration
      *1 Double-sided Tape

      Engage the 19 clips and install a new front door weatherstrip.

  11. 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. A019M4X

      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 }

  12. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A019KM1E01

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

  13. 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. A019P80

      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 }

  14. INSTALL ELECTRICAL KEY WIRE HARNESS


    1. A019KZ4

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

    2. Connect the connector.

  15. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A019O3P

      Install the front door inside locking cable assembly.

    2. A019K2B

      Engage the 3 claws.

  16. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A019OVL

      Install the front door lock remote control cable assembly.

  17. 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. A019OFE

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

    3. A019P4H

      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 }

  18. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A019NRD

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

  19. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A019KIR

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

  20. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A019KJY

      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. A019LCT

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

    4. A019LQ9

      Connect the connector.

    5. Engage the 2 claws.

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


    1. A019P18

      Engage the claw and install the front door outside handle cover to the front door lock cylinder.

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


    1. A019OFL

      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. A019OEZ

      Install the hole plug.

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


    1. A019JSC

      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. A019OC2

      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. A019OT4

      Install the hole plug.

  24. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A019JZA

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

  25. INSTALL FRONT DOOR GLASS RUN


    1. A019ODG

      Install the front door glass run.

  26. 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. A019P3M

      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.

  27. 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. A019K7NE02
      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.

  28. 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 subassembly so that the door glass bolts can be seen.


      1. w/ Navigation System for HDD:

        Note

        After the engine 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 engine switch off, make sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) battery terminal.

        Waiting Time before Disconnecting Cable from Negative (-) Battery Terminal
        Specification Waiting Time
        w/o Telematics transceiver 60 sec.
        w/ Telematics transceiver 120 sec.

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

      CAUTION:

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

    4. A019M1SE01

      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. A019KOBE01

      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.

  29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY


    1. A019P39

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

    2. w/o Side Monitor System:


      1. A019LF7

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

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

      2. Engage the clamp as shown in the illustration.

    3. w/ Side Monitor System:


      1. A019P2U

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

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

      2. Engage the clamp as shown in the illustration.

      3. Connect the connector.

  30. INSTALL OUTER MIRROR INSTALL HOLE COVER


    1. A019OWY

      Engage the 2 claws and 2 guides to install the outer mirror install hole cover as shown in the illustration.

  31. INSTALL OUTER MIRROR PROTECTOR


    1. A019LF8

      Install a new outer mirror protector.

  32. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the front door panel.

    2. A019LWRE01
      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.

    4. Connect the connector.

  33. INSTALL NO. 1 FRONT DOOR TRIM BRACKET


    1. A019PA1

      Install the 2 bolts and No. 1 front door trim bracket.

  34. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY


    1. A019K78

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

    2. Connect each connector.

  35. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


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

    2. Connect the connector.

  36. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY


    1. Engage the clip and temporarily install the front No. 3 speaker assembly.

    2. Install the front No. 3 speaker assembly with the 2 screws.

    3. Connect the connector.

  37. INSTALL DOOR FRAME GARNISH


    1. A019KMZ

      Install the door frame garnish with the 2 clips.

  38. INSTALL FRONT DOOR TRIM POCKET


    1. A019K9K

      Install the front door trim pocket with the 7 screws.

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


    1. A019LRS

      Install the seat memory switch with the 2 screws.

  40. INSTALL FRONT DOOR SPEAKER GRILLE SUB-ASSEMBLY


    1. A019OOC

      Bend the claws as shown in the illustration to install the front door speaker grille sub-assembly.

  41. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY


    1. Install the front No. 2 speaker assembly with the 2 screws.

    2. Engage the clamp.

  42. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A019MJY

      Engage the 4 claws and install the front door inner glass weatherstrip as shown in the illustration.

  43. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. Install a new front door trim board retainer (green).

    2. A019MHA

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

    3. Connect each connector.

    4. A019OC3

      Engage the front door trim board sub-assembly with the 4 claws of the front door inner glass weatherstrip as shown in the illustration.

    5. A019M4HE01
      Text in Illustration
      *1 Front Door Trim Board Retainer

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

    6. Install the 3 screws.

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

  44. INSTALL NO. 1 FRONT DOOR STIFFENER CUSHION


    1. A019M7L

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

  45. INSTALL COURTESY LIGHT ASSEMBLY


    1. Connect the connector.

    2. A019M9AE02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Engage the claw to install the courtesy light assembly.

  46. INSTALL DOOR ARMREST COVER


    1. A019NO5

      Install the door armrest cover.

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


    1. A019NBB

      Connect the connector.

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

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


    1. A019L9Q

      Connect the connector.

    2. Engage the 2 clips and 5 claws, and install the power window regulator switch assembly with front door armrest base panel.

  49. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A019M5M

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

  50. INSPECT FRONT DOOR


    1. Check that the clearance measurements of areas *1 through *32 are within each standard range.

      A019OSQE01
      Standard Clearance
      Area Measurement Area Measurement
      *1 3.5 to 6.5 mm (0.138 to 0.256 in.) *2 3.5 to 6.5 mm (0.138 to 0.256 in.)
      *3 3.7 to 6.7 mm (0.146 to 0.264 in.) *4 3.5 to 6.5 mm (0.138 to 0.256 in.)
      *5 2.0 to 5.0 mm (0.0787 to 0.197 in.) *6 3.5 to 6.5 mm (0.138 to 0.256 in.)
      *7 1.2 to 4.2 mm (0.0472 to 0.165 in.) *8 3.5 to 6.5 mm (0.138 to 0.256 in.)
      *9 0.5 to 3.5 mm (0.0197 to 0.138 in.) *10 5.5 mm (0.217 in.)
      *11 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *12 3.0 to 6.0 mm (0.118 to 0.236 in.)
      *13 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *14 3.0 to 6.0 mm (0.118 to 0.236 in.)
      *15 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *16 3.2 to 6.2 mm (0.126 to 0.244 in.)
      *17 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *18 3.2 to 6.2 mm (0.126 to 0.244 in.)
      *19 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *20 3.2 to 6.2 mm (0.126 to 0.244 in.)
      *21 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *22 3.0 to 7.0 mm (0.118 to 0.276 in.)
      *23 5.5 to 10.5 mm (0.217 to 0.413 in.) *24 3.2 to 6.2 mm (0.126 to 0.244 in.)
      *25 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.) *26 5.5 to 10.5 mm (0.217 to 0.413 in.)
      *27 2.8 to 5.8 mm (0.110 to 0.228 in.) *28 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.)
      *29 2.8 to 5.8 mm (0.110 to 0.228 in.) *30 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.)
      *31 2.8 to 5.8 mm (0.110 to 0.228 in.) *32 -1.5 to 1.5 mm (-0.0591 to 0.0591 in.)

  51. ADJUST FRONT DOOR


    1. A019M94

      Using SST, loosen the hinge bolts on the vehicle body and adjust the door position.

      SST
      09812-00010

    2. Tighten the hinge bolts on the vehicle body after the adjustment.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

    3. Loosen the hinge bolts on the door and adjust the door position.

    4. Tighten the hinge bolts on the door after the adjustment.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    5. A019MPYE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, disengage the 4 claws and remove door lock striker cover.

      Tech Tips

      Tape the screwdriver tip before use.

    6. A019NWA

      Using a T40 "TORX" socket wrench, slightly loosen the striker mounting screws.

    7. Using a brass bar and a hammer, hit the striker to adjust its position.

    8. Using a T40 "TORX" socket wrench, tighten the striker mounting screws after the adjustment.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    9. A019JZK

      Engage the 4 claws and install the door lock striker cover.

  52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  53. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  54. INSPECT SRS WARNING LIGHT

    Click here

  55. ADJUST SIDE TELEVISION CAMERA OPTICAL AXIS (CAMERA POSITION SETTING) (w/ Side Monitor System)

    Click here