FRONT DOOR REASSEMBLY

Tech Tips

Use the same procedure for RHD and LHD vehicles.
The procedure listed below is for LHD vehicles.
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.

INSTALL FRONT DOOR CHECK ASSEMBLY LH
1. Apply MP grease to the sliding areas of the front door check.
2. When reusing a bolt labeled B:
  1. Clean the threads of the bolt labeled B with non-residue solvent.
  2. Apply adhesive to the threads of the bolt labeled B.
    
    Adhesive
    
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
3. Text in Illustration
  
  *1 Bolt A
  
  *2 Bolt B
  
  Install the front door check with the 2 bolts labeled A and the bolt labeled B.
  
  Torque:
  
  Bolt A
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
  
  Bolt B
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }

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

Text in Illustration
*1	Bolt A
*2	Bolt B

INSTALL FRONT DOOR WEATHERSTRIP LH

Tech Tips

When installing the front door weatherstrip, 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.

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.
Install a new front door weatherstrip.
1. for Double Cab:
  1. Remove the peeling paper from the face of the front door weatherstrip.
    
    Tech Tips
    
    After removing the peeling paper, keep the exposed adhesive free from foreign matter.
  2. Attach the 33 clips to install the front door weatherstrip.
    
    Tech Tips
    
    Press the front door weatherstrip firmly to install it.
  3. Install the clip.
2. for Single Cab, for Extra Cab:
  1. Remove the peeling paper from the face of the front door weatherstrip.
    
    Tech Tips
    
    After removing the peeling paper, keep the exposed adhesive free from foreign matter.
  2. Attach the 34 clips to install the front door weatherstrip.
    
    Tech Tips
    
    Press the front door weatherstrip firmly to install it.
  3. Install the clip.

INSTALL FRONT DOOR PANEL CUSHION
1. Install a new front door panel cushion.
INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Attach the 2 claws to install the front door rear outside handle pad.
INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Attach the 2 claws to install the front door front outside handle pad.
INSTALL FRONT DOOR LOCK OPEN ROD LH
1. Text in Illustration
  
  *1 Snap
  
  Install the front door lock open rod to the front door outside handle frame.
2. Rotate the snap in the direction indicated by the arrow in the illustration to attach the snap to the front door lock open rod.
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 claw to install the front door outside handle frame.
3. Using a T30 "TORX" socket wrench, install the screw.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 36 in.*lbf }
INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH
1. Install the front door outside handle by moving it in the direction indicated by the arrow shown in the illustration.
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.
INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH
1. Install the front door lock remote control cable.
INSTALL FRONT DOOR LOCK ASSEMBLY LH
1. w/ Power Window:
  1. Using a T30 "TORX" socket wrench, install the front door lock with the 3 screws.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  2. Connect the front door inside locking cable and front door lock remote control cable to the clamps.
  3. Connect the connector.
2. w/o Power Window:
  1. Using a T30 "TORX" socket wrench, install the front door lock with the 3 screws.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  2. Connect the front door inside locking cable and front door lock remote control cable to the clamps.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER
1. Attach the 2 claws to install the front door outside handle cover to the door key cylinder.
2. Using a T30 "TORX" socket wrench, install the front door outside handle cover together with the door key cylinder with the screw.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 36 in.*lbf }
3. Install the hole plug.
INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH
1. Install the front door rear lower frame with the 2 nuts.
INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH (w/ Power Window)
1. Using a T25 "TORX" socket wrench, install the power window regulator motor with the 3 screws.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
1. w/ Power Window:
  1. Apply MP grease to the sliding and rotating areas of the front door power window regulator.
  2. Temporarily install the temporary bolt to the front door power window regulator.
  3. Text in Illustration
    
    *1 Temporary Bolt
    
    Install the front door power window regulator with the 5 bolts, and then tighten the temporary bolt.
    
    Torque:
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
    
    Note
    
    Be careful not to drop the front door power window regulator as it may become damaged.
  4. Connect the connector.
2. w/o Power Window:
  1. Apply MP grease to the sliding and rotating areas of the front door window regulator.
    
    Note
    
    Do not apply grease to the spring of the window regulator.
  2. Temporarily install the temporary bolt to the front door window regulator.
  3. Text in Illustration
    
    *1 Temporary Bolt
    
    Install the front door window regulator with the 4 bolts, and then tighten the temporary bolt.
    
    Torque:
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
    
    Note
    
    Be careful not to drop the front door power window regulator as it may become damaged.
INSTALL FRONT DOOR GLASS RUN LH
1. Install the front door glass run.
INSTALL FRONT DOOR OUTER GLASS WEATHERSTRIP ASSEMBLY LH
1. Attach the 5 claws to install the front door outer glass weatherstrip.
INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
1. w/ Power Window:
  1. Temporarily install the power window regulator master switch assembly with front door armrest base panel.
  2. Connect the cable to the negative (-) 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 (-) 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.
2. w/o Power Window:
  1. Temporarily install the front door window regulator handle.
  2. Operate the front door window regulator so that the front door glass can be installed.
  3. Remove the front door window regulator handle.
3. 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.
4. Install the front door glass with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL FRONT DOOR SERVICE HOLE COVER LH
1. Apply new butyl tape to the front door panel.
2. Text in Illustration
  
  *a Reference Point
  
  Pass the front door inside locking cable, front door lock remote control cable and wire harness through a new front door service hole cover, and then install the front door service hole cover using the reference points on the front door panel.
INSTALL FRONT DOOR NO. 1 TRIM BRACKET
1. Install the front door No. 1 trim bracket with the 2 screws.
INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH
1. Connect the front door inside locking cable and front door lock remote control cable to the front door inside handle.
2. Attach the 2 guides as indicated by the arrow in the illustration, and then attach the claw to install the front door inside handle.
INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
1. Install the outer rear view mirror assembly LH with the 3 nuts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 ft.*lbf }
2. w/ Power Mirror Control System:
  
  Connect the connector.

Text in Illustration
*1	Snap

Text in Illustration
*1	Temporary Bolt

Text in Illustration
*1	Temporary Bolt

Text in Illustration
*a	Reference Point

INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

Install a nose piece to an air riveter or hand riveter. Then insert the mandrel part of a new φ4 mm waterproof rivet into the nose piece.

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	Mandrel
*2	Riveter
*a	INCORRECT
*b	CORRECT

Confirm that the rivets are seated properly against the speaker.

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

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	Riveter
*a	INCORRECT
*b	CORRECT

Connect the connector.

INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (w/ Front No. 2 Speaker)
1. Install the speaker with the screw.
2. Connect the connector.
INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH
1. for Double Cab:
  1. Install the front door inner glass weatherstrip to the front door trim board and fold down the 7 claws in the directions indicated by the arrows in the illustration.
2. for Single Cab, for Extra Cab:
  1. Install the front door inner glass weatherstrip to the front door trim board and fold down the 8 claws in the directions indicated by the arrows in the illustration.
INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
1. for Double Cab:
  1. Attach the 8 clips to install the front door trim board.
  2. Install the screw and clip.
2. for Single Cab, for Extra Cab:
  1. Attach the 9 clips to install the front door trim board.
  2. Install the screw and clip.
INSTALL DOOR PULL HANDLE
1. Install the door pull handle with the screw.
INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH
1. Attach the 2 clips to install the front door lower frame bracket garnish.
INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (w/ Power Window)
1. Connect the connector.
2. Attach the 4 claws and 2 clips to install the power window regulator switch assembly with front door armrest base panel.
INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (w/ Power Window, for Passenger Side)
1. Connect the connector.
2. Attach the 4 claws and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.

INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)

Temporarily install the front door window regulator handle, fully close the window, and then remove the front door window regulator handle.

Text in Illustration
*1	Snap Ring
*2	Plate
*a	Front Side

Install the plate and snap ring to the front door window regulator handle.

Install the front door window regulator handle to the front door window regulator as shown in the illustration.

Standard

Area	Specified Condition
A	18 to 42°

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/ Power Window)

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INITIALIZE POWER WINDOW CONTROL SYSTEM (w/ Jam Protection Function)

Click here