FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The procedure described below is for the LH side.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

  2. REPAIR INSTRUCTION

    Click here

  3. INSTALL NO. 1 BLACK OUT TAPE

    Click here

  4. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

    Click here

  5. INSTALL FRONT DOOR REAR OUTSIDE STRIPE

    Click here

  6. INSTALL FRONT DOOR STRIPE

    Click here

  7. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

    Click here

  8. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

    Click here

  9. INSTALL FRONT DOOR PANEL CUSHION


    1. A005D73

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

  10. INSTALL FRONT DOOR WEATHERSTRIP


    1. A005F2K

      Engage the 17 clips and install the front door weatherstrip.

  11. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. A005BQ6E03

      Apply adhesive to the threads of the bolt (A).

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Install the front door check assembly with the 3 bolts.

      Torque:
      (A)
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      (B)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  12. INSTALL DOOR FRAME GARNISH


    1. A005EFD

      Engage the clip to install a new door frame garnish.

  13. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A005EVWE03

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

  14. INSTALL FRONT DOOR WIRE (w/ Entry and Start System)


    1. A005CRE

      Engage the 2 clamps to install the front door wire.

  15. 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. A005E88E03
      Text in Illustration
      *a Outside
      *b Inside

      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 }

    4. w/ Entry and Start System:


      1. A005CH0

        Engage the clamp.

      2. Connect the connector.

  16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A005C5E

      Install the front door inside locking cable assembly as shown in the illustration.

    2. A005DO9

      Engage the 3 claws as shown in the illustration.

  17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A005A66

      Install the front door lock remote control cable assembly as shown in the illustration.

  18. 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. When reusing the front door lock assembly:


      1. A005EI5

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

    3. A005CXDE01
      Text in Illustration
      *1 Front Door Lock Open Rod

      Insert the front door lock open rod to the front door lock assembly.

      Tech Tips

      Make sure that the front door lock open rod is securely connected to the front door lock assembly.

    4. 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 }

    5. Connect the connector.

  19. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A005EOQ

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

  20. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A0059PE

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

  21. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A005F2I

      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. A005C9N

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

    4. w/ Entry and Start System:


      1. A005BX0

        Connect the connector.

      2. Engage the 2 claws.

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


    1. A005CZN

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

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


    1. A005AWX

      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. A005C15

      Install the hole plug.

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


    1. A005BM7

      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. A005A3F

      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. A005EPE

      Install the hole plug.

  25. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A005EW3

      Engage the guide as shown in the illustration.

    2. Install the front door rear lower frame sub-assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  26. INSTALL FRONT DOOR GLASS RUN


    1. A005BY2

      Install the front door glass run.

  27. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

    The regulator arm must be below the intermediate position when installing the power window regulator motor.


    1. A005CEX

      Using a T25 "TORX" socket wrench, install the 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.

  28. INSTALL FRONT DOOR POWER WINDOW REGULATOR ASSEMBLY


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

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

    3. A005EOCE04
      Text in Illustration
      *1 Temporary Bolt

      Temporarily install the front door power window regulator assembly.

    4. Tighten the temporary bolt and 5 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    5. Connect the connector.

  29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


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

    2. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

    3. Disconnect the cable from the negative (-) auxiliary battery terminal and multiplex network master switch assembly.

    4. A005DKOE03

      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. A005EJR

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. A005D92

      Install the grommet.

  30. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. A005AZ4E01
      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.

  31. INSTALL FRONT DOOR TRIM BRACKET


    1. A005AZL

      Install the front door trim bracket with the 2 screws.

  32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  33. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

    Click here

  34. INSTALL OUTER MIRROR INSTALL HOLE COVER

    Click here

  35. INSTALL OUTER MIRROR PROTECTOR

    Click here

  36. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  37. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A005BV6

      Engage the 2 claws to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

  38. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A005AC0

      Engage the 7 claws to install the front door inner glass weatherstrip to the front door trim board sub-assembly as shown in the illustration.

  39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A005E7TE03
      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 the courtesy light connector.

    3. A005C28

      Engage the 9 clips and install the front door trim board sub-assembly.

    4. Install the 2 screws.

    5. If protective tape has been applied, remove it.

  40. INSTALL DOOR ARMREST COVER


    1. A005DU9

      Install the door armrest cover.

  41. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)


    1. Connect the connector.

    2. A005CGE

      Engage the 4 guides, 11 claws and clip to install the multiplex network master switch assembly with front door armrest base panel.

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


    1. Connect the connector.

    2. A005DSA

      Engage the 4 guides, 11 claws and clip to install the power window regulator switch assembly with front door armrest base panel.

  43. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A0059ZE

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

  44. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  45. INSTALL DECK FLOOR BOX RH

    Click here

  46. INSTALL REAR DECK FLOOR BOX

    Click here

  47. INSTALL NO. 1 DECK BOARD

    Click here

  48. INSTALL NO. 2 DECK BOARD

    Click here

  49. INSTALL DECK BOARD ASSEMBLY

    Click here

  50. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  51. INSPECT POWER WINDOW OPERATION

    Click here