FRONT DOOR INSTALLATION

Tech Tips

Use the same procedure for the RH and LH sides.
The procedure listed below is for the LH side.

REPAIR INSTRUCTION
1. Clean the vehicle body surface.
  1. Using a heat light, heat the vehicle body surface.
  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 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 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 falls off easily. When the temperature is high, the tape loses elasticity.
3. Before installation.
  1. Make sure any dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame) is removed, and that the surface is smooth. If the surface is rough 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 level.
    
    Note
    
    Do not bend the tape or leave it in high temperature places.
5. Key points for the installation of the tape (how to use a squeegee and the installation procedure for flat surfaces).
  Note
  
  Position the tape with a high level of accuracy to achieve a neat finish and to avoid peeling.
  
  The tape cannot be reused because it deforms and will not fit after removal.
  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 40 to 50° (for pressing forward) or 30 to 45° (for pulling) from the vehicle body surface and press with a force of 20 to 30 N (2 to 3 kgf) while moving the squeegee at a constant slow speed of 3 to 7 cm (1.2 to 2.8 in.) per second.
    
    Note
    
    Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles and air bubbles.
    
    Tech Tips
    
    Either angle of the squeegee (for pressing forward or for pulling) is acceptable.
    
    Be sure to apply the tape while removing the release paper 10 to 20 mm (0.393 to 0.787 in.) from the edge of the squeegee.
6. Key points for the installation of the tape (how to use a squeegee and the installation procedure for hemming surfaces).
  1. If it is difficult to press the tape, press 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 the installation of the tape (how to use a squeegee and the 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 to avoid wrinkles on the tape and 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, apply new tape.
    
    Note
    
    Do not reuse the tape.

INSTALL NO. 2 BLACK OUT TAPE LH

Refer to the illustration to position a new No. 2 black out tape.

Standard

Area	Dimension
A	2 to 4 mm (0.078 to 0.158 in.)
B	5 mm (0.197 in.)
C	5 mm (0.197 in.)
D	2 to 4 mm (0.078 to 0.158 in.)

Remove the release paper and apply the tape.

INSTALL NO. 1 BLACK OUT TAPE LH

Refer to the illustration to position a new No. 1 black out tape.

Standard

Area	Dimension
A	2 to 4 mm (0.078 to 0.158 in.)
B	5 mm (0.197 in.)

Remove the release paper and apply the tape.

INSTALL FRONT DOOR WEATHERSTRIP LH
1. Attach the 14 clips to install the weatherstrip.
2. Install the clip labeled A.
INSTALL FRONT DOOR CHECK ASSEMBLY LH
1. Apply MP grease to the sliding areas of the door check.
2. Install the door check to the door panel with the 2 nuts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
3. Apply adhesive to the threads of the bolt.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
4. Install the bolt.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
INSTALL FRONT DOOR LOCK OPEN ROD LH
1. Install the front door lock open rod as shown in the illustration.
INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.
2. w/ Entry and Start System:
  1. Attach the 2 clamps and 2 claws to attach the front door outside handle frame to the front door wire.
  2. Attach the 2 claws to install the front door outside handle frame sub-assembly.
  3. Using a T30 "TORX" wrench, tighten the screw.
    
    Torque:
    
    4.0 N*m { 41 kgf*cm, 35 in.*lbf }
  4. Attach the 3 clamps.
3. w/o Entry and Start System:
  1. Attach the 2 claws to install the front door outside handle frame sub-assembly.
  2. Using a T30 "TORX" wrench, tighten the screw.
    
    Torque:
    
    4.0 N*m { 41 kgf*cm, 35 in.*lbf }
INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH
1. Install the front door inside locking cable assembly.
2. Attach the 3 claws.
INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH
1. Install the front door lock remote control cable.
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 surface of the connector which contacts the door lock wiring harness seal.
- Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may allow water into the connection. 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. Insert the front door lock open rod into the front door lock assembly.
4. Check that the front door lock open rod is securely connected to the front door lock assembly.
5. Using a T30 "TORX" wrench, install the front door lock assembly with the 3 screws.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Attach the 2 claws to install the pad.
INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Attach the 3 claws to install the pad.

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

w/ Entry and Start System:

Install the handle by pushing it in the direction of the arrow in the illustration.

Text in Illustration
*1	Holder
*2	Front Door Outside Handle Frame LH
*3	Front Door Outside Handle Connector

Attach the holder of the front door outside handle frame LH.

Text in Illustration
*1	Connector Cover
*2	Front Door Outside Handle Frame LH
*3	Front Door Wire LH

Connect the front door wire connector and attach the claw of the connector to the front door outside handle.

Text in Illustration
*1	Connector Cover
*2	Front Door Outside Handle Frame LH
*3	Front Door Wire LH

Attach the 2 claws to fix the connector cover in place.

w/o Entry and Start System:

Install the handle by pushing it in the direction of the arrow in the illustration.

Text in Illustration
*1	Holder
*2	Front Door Outside Handle Frame LH

Attach the holder of the front door outside handle frame LH.

INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (for Driver Side)
1. Attach the 3 claws to install the front door outside handle cover to the front door lock key cylinder.
2. Tighten the screw using a T30 "TORX" socket to install the cover (with the door lock key cylinder).
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
3. Install the hole plug.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER RH (for Front Passenger Side)
1. Tighten the screw using a T30 "TORX" socket to install the cover.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Install the hole plug.
INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH
1. Install the rear lower frame with the bolt.
  
  Torque:
  
  6.2 N*m { 63 kgf*cm, 55 in.*lbf }
INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH
1. Attach the 6 claws to install the front door belt moulding.
2. Install the clip.
INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY LH
1. Apply MP grease to the sliding and rotating areas of the window regulator.
  
  Note
  
  Do not apply grease to the spring of the window regulator.
2. Text in Illustration
  
  *1 Temporary Bolt
  
  Temporarily install the temporary bolt to the window regulator.
3. Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.
  
  Note
  
  Be careful not to drop the window regulator as it may become damaged.
4. Temporarily install the window regulator with the 5 bolts.
5. Tighten the 6 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL DOOR FRAME GARNISH LH
1. Attach the clip to install a new door frame garnish.
INSTALL FRONT DOOR GLASS RUN LH
1. Install the front door glass run.
INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
1. for Driver Side:
  
  Temporarily install the master switch assembly.
2. for Front Passenger Side:
  
  Temporarily install the regulator switch assembly.
3. Connect the cable to the negative (-) battery terminal.
4. Move the door glass until the bolts appear in the service holes.
5. 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.
6. Insert the door glass into the door panel along the glass run as indicated by the arrows in the illustration.
  
  Note
  
  Be careful not to damage the glass.
7. Install the door glass to the window regulator with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }

Text in Illustration
*1	Temporary Bolt

INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

Note

Do not touch the cone part of the speaker.

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

Using an air riveter or hand riveter, install the speaker with 3 new rivets.

Note

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

Text in Illustration
*1	INCORRECT
*2	CORRECT
*3	Mandrel
*4	Riveter

Confirm that the rivets are seated properly against the speaker.

Text in Illustration
*1	INCORRECT
*2	CORRECT
*3	Riveter

Do not tilt the riveter when installing the rivet to the speaker.
Do not leave any space between the rivet head and speaker.

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

Text in Illustration
*1	INCORRECT
*2	CORRECT
*3	Riveter

Connect the connector.

INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
1. Attach the claw to install the outer rear view mirror assembly LH, and then install the 3 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
2. Attach the clamp.
3. Connect the connector.
INSTALL FRONT DOOR SERVICE HOLE COVER LH
1. Apply butyl tape to the door.
2. Pass the front door lock remote control cable and front door inside locking cable through a new front door service hole cover.
3. Text in Illustration
  
  *1 Reference Point
  
  Install 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 to prevent wrinkles and air bubbles.
  
  There should be no wrinkles or folds after installing the service hole cover.
  
  After installing the service hole cover, check the seal quality.
4. Connect the 2 connectors.
INSTALL OUTER MIRROR INSTALL HOLE COVER LH
1. Attach the 3 claws to install the outer mirror install hole cover.
INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH
1. Install the front door inner glass weatherstrip.
INSTALL FRONT DOOR LOWER TRIM COVER (w/o Courtesy Light)
1. Attach the 2 claws to install the front door lower trim cover.
INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)
1. Install the bulb.
2. Connect the connector.
3. Attach the claw to install the light.
INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH
1. Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle sub-assembly to install the inside handle.
INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
1. Attach the 2 claws to install the front door inside handle sub-assembly to the door trim board.
2. Attach the front door trim board with the 5 claws of the front door inner glass weatherstrip and the reference boss.
3. w/ Courtesy Light:
  1. Connect the courtesy light connector.
4. Attach the 9 clips to install the trim board.
5. Install the 3 screws.

Text in Illustration
*1	Reference Point

INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)

Text in Illustration
*1	w/ Rear Door Power Window
*2	w/o Rear Door Power Window

w/ Rear Door Power Window:

Attach the 4 claws to install the master switch assembly.
Install the 3 screws.

w/o Rear Door Power Window:
1. Install the master switch assembly with the 3 screws.

INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)
1. Attach the 2 claws to install the regulator switch.
INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)
1. Connect the connector.
2. Attach the 7 claws and clip to install the power window regulator master switch assembly with front door armrest base panel.
INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)

Tech Tips

Use the same procedure described for the driver side.
INSTALL FRONT DOOR TRIM MOULDING LH
1. Attach the 8 claws to install the front door trim moulding.
INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH
1. Attach the 3 claws to install the inside handle bezel.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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