FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tip:

  • 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).

PROCEDURE

  1. INSTALL FRONT DOOR PANEL CUSHION

    1. Attach the clip to install a new door panel cushion.

  2. INSTALL LOWER FRONT DOOR OUTSIDE STRIPE LH

    Click here

  3. INSTALL FRONT DOOR OUTSIDE STRIPE LH

    Click here

  4. INSTALL NO. 1 BLACK OUT TAPE LH

    Click here

  5. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

    Click here

  6. INSTALL FRONT DOOR BELT MOULDING LH

    Click here

  7. INSTALL FRONT DOOR WEATHERSTRIP LH

    Tip:

    When installing the front door weatherstrip, heat the vehicle body and front door weatherstrip using a heat light.

    Note:

    Do not heat the vehicle body or front door weatherstrip excessively.

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

      Heating Temperature

      Item

      Temperature

      Vehicle Body

      40 to 60°C (104 to 140°F)

      Front Door Weatherstrip

      20 to 30°C (68 to 86°F)

    2. Remove the double-sided tape from the vehicle body.

    3. Wipe off any tape adhesive residue with cleaner.

    4. B253863C01

      *1

      Double-sided tape

      Attach the 21 clips and double-sided tape to install a new front door weatherstrip.

      Tip:

      Press the front door weatherstrip firmly to install it.

  8. INSTALL FRONT DOOR CHECK ASSEMBLY LH

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

    2. B238556

      Install the door check to the door panel with the 2 nuts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    3. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the front door check assembly with the bolt.

      27 N*m

      275 kgf*cm

      20 ft.*lbf

  9. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

    1. Clean the installation surface.

      1. Using a heat light, heat the installation surface.

        Standard

        Item

        Temperature

        Vehicle body

        40 to 60°C (104 to 140°F)
        Note:

        Do not heat the vehicle body excessively.

      2. Remove the double-sided tape from the installation surface.

      3. Wipe off any tape adhesive residue with cleaner.

    2. Install a new door stiffener cushion.

      1. Using a heat light, heat a new front door No. 2 stiffener cushion and the installation surface.

        Tip:

        When installing the front door No. 2 stiffener cushion, heat the vehicle body and door stiffener cushion using a heat light.

        Standard

        Item

        Temperature

        Door stiffener cushion

        20 to 30°C (68 to 86°F)

        Vehicle body

        40 to 60°C (104 to 140°F)
        Note:

        Do not heat the door stiffener cushion and vehicle body excessively.

      2. Remove the peeling paper from the face of the door stiffener cushion.

        Tip:

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

      3. Attach the 2 clamps and double-sided tape to install the front door No. 2 stiffener cushion.

        Tip:

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

      4. Install the 2 bolts.

  10. INSTALL FRONT DOOR LOCK OPEN ROD LH

    1. B311737N01

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

  11. INSTALL FRONT DOOR NO. 2 WIRE LH

    1. B238552

      Attach the 4 clamps to install the front door No. 2 wire.

  12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

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

    2. B241222

      Attach 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.

      4.0 N*m

      41 kgf*cm

      35 in.*lbf

    4. B238551

      Attach the clamp.

    5. Connect the front door No. 2 wire connector to the front door wire.

  13. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH

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

  14. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH

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

  15. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

    1. B241223

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

    3. B241224

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

    4. B238541

      Connect the connector.

    5. Attach the 2 claws.

  16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

    1. Install the front door inside locking cable assembly.

    2. Attach the 3 claws.

  17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

    1. Install the front door lock remote control cable assembly.

  18. INSTALL FRONT DOOR LOCK ASSEMBLY LH

    Click here

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

    1. B238540

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

      4.0 N*m

      41 kgf*cm

      35 in.*lbf

    2. B241166

      Install the hole plug.

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

    1. B241225

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

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

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

      Tip:

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

    2. B238538

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

      4.0 N*m

      41 kgf*cm

      35 in.*lbf

    3. B238537

      Install the hole plug.

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

    1. B249666

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

  23. INSTALL DOOR FRAME GARNISH LH

    1. B238558

      Attach the clip to install a new door frame garnish.

  24. INSTALL FRONT DOOR GLASS RUN LH

    1. B249647

      Install the front door glass run.

  25. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

    Click here

  26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

    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. B311738C01

      *1

      Temporary Bolt

      Temporarily install the front door window regulator assembly with the temporary bolt.

    4. Temporarily install the 5 bolts, and then tighten the temporary bolt and 5 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

      Tip:

      Tighten the bolts in the order shown in the illustration.

    5. Connect the connector.

  27. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

    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 installation locations can be seen.

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

      Note:

      • w/ Navigation System (for HDD):

        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, be 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

        Condition

        Waiting Time

        Vehicle enrolled in G-BOOK system

        6 minutes

        Vehicle not enrolled in G-BOOK system

        1 minute

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

    4. B311739N01

      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. B238531N01

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

      Tip:

      Tighten the bolts in the order shown in the illustration.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  28. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

    Click here

  29. INSTALL FRONT DOOR SERVICE HOLE COVER LH

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

    2. B238607C01

      *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 using the reference points on the front door panel.

      Note:

      • There should be no wrinkles or folds after attaching the service hole cover.

      • After attaching the service hole cover, check the seal quality.

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

    4. B249646

      Attach the 2 clamps.

    5. Install the bolt to the front door wire.

      8.5 N*m

      87 kgf*cm

      75 in.*lbf

  30. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY

    Click here

  31. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH

    Click here

  32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  33. INSTALL SEAT MEMORY SWITCH

    Click here

  34. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH

    Note:

    When removing the inside handle sub-assembly, do not damage the door trim.

    1. Insert the edge of the assist grip from the front of the trim and rotate the assist grip together with the inside handle sub-assembly to attach the 2 guides.

    2. Attach the 9 guides to install the assist grip together with the inside handle sub-assembly.

    3. Install the 14 screws.

  35. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)

    Click here

  36. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side)

    Click here

  37. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH

    Click here

  38. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  39. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH

    1. B249669

      Install the front door inner glass weatherstrip.

  40. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

    1. B241244

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

    2. Connect 2 connectors.

    3. B249670

      Attach the front door trim board sub-assembly by attaching the 4 claws of the front door inner glass weatherstrip as shown in the illustration.

    4. B249645

      Attach the 12 clips and front door trim board retainer to install the front door trim board sub-assembly.

    5. Install the 3 screws.

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

    1. Connect the connector.

    2. Attach the 2 clips, 4 claws and guide to install the power window regulator master switch assembly with front door armrest base panel.

  42. INSTALL FRONT ARMREST ASSEMBLY LH

    1. Attach the 7 claws and 7 guides to install the front armrest assembly.

  43. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

    1. Attach the 2 claws to install the front door lower frame bracket garnish.

  44. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH

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

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

  46. INITIALIZE POWER WINDOW CONTROL SYSTEM

    1. Initialize the power window control system (Click here).

  47. CHECK SRS WARNING LIGHT

    1. Check the SRS warning light (Click hereClick hereClick here).