FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The following procedure 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 DUST PROOF SEAL


    1. B005Z1C

      Engage the claw to install a new front door dust proof seal as shown in the illustration.

      Note

      Install the front door dust proof seal with the arrow facing up.

      Tech Tips

      Use the same procedure for the other 2 front door dust proof seals.

  10. INSTALL FRONT DOOR PANEL CUSHION


    1. B005ZTP

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

  11. INSTALL FRONT DOOR WEATHERSTRIP


    1. B005YV3

      Engage the 17 clips and install the front door weatherstrip.

  12. INSTALL FRONT DOOR CHECK ASSEMBLY


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

    2. B005XEHE03

      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 }

  13. INSTALL DOOR FRAME GARNISH


    1. B005YB0

      Engage the clip to install a new door frame garnish.

  14. INSTALL FRONT DOOR LOCK OPEN ROD


    1. B005YY5E03

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

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


    1. B005YGS

      Engage the 2 clamps to install the front door wire.

  16. 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. B005XFCE03
      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. B005YXH

        Engage the clamp.

      2. Connect the connector.

  17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)


    1. B005Z7K

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

  18. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)


    1. B005XS6

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

    2. B005YA4

      Engage the 3 claws as shown in the illustration.

  19. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)


    1. B005YYP

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

  20. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)


    1. B005Y88

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

  21. INSTALL FRONT DOOR LOCK COVER SUB-ASSEMBLY (w/o Double Locking System)


    1. B005YV6

      Engage the 2 claws.

    2. B005ZHF

      Engage the 2 claws to install the front door lock cover sub-assembly as shown in the illustration.

  22. INSTALL FRONT DOOR LOCK ASSEMBLY

    Note


    • When reusing a removed front door lock assembly, replace the door lock wiring harness seal with a new one.

    • Do not allow grease or dust to adhere to the door lock wiring harness seal installation surface.

    • Reusing a door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water ingress. 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. B005YSU

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

    3. B005XZNE01
      Text in Illustration
      *1 Front Door Lock Open Rod

      Connect 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.

  23. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. B005Z16

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

  24. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. B005YKQ

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

  25. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. B005ZVB

      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. B005ZPM

      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. B005ZMX

        Connect the connector.

      2. Engage the 2 claws.

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


    1. B005YX2

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

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


    1. B005XWR

      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. B005YTG

      Install the hole plug.

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


    1. B005ZQ8

      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. B005ZBY

      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. B005YTN

      Install the hole plug.

  29. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. B005YOF

      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 }

  30. INSTALL FRONT DOOR GLASS RUN


    1. B005XW9

      Install the front door glass run.

  31. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

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


    1. B005Y2K

      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.

  32. 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. B005YKGE04
      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.

  33. 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. B005ZT3E03

      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. B005XGL

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. B005XS8

      Install the grommet.

  34. INSTALL FRONT DOOR SERVICE HOLE COVER


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

    2. B005Z4WE01
      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.

  35. INSTALL FRONT DOOR TRIM BRACKET


    1. B005XJO

      Install the front door trim bracket with the 2 screws.

  36. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

    Click here

  37. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

    Click here

  38. INSTALL OUTER MIRROR INSTALL HOLE COVER

    Click here

  39. INSTALL OUTER MIRROR PROTECTOR

    Click here

  40. INSTALL COURTESY LIGHT ASSEMBLY

    Click here

  41. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. B005ZKR

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

  42. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. B005Z3O

      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.

  43. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. B005XO5E03
      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. B005XVD

      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.

  44. INSTALL DOOR ARMREST COVER


    1. B005YGD

      Install the door armrest cover.

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


    1. Connect the connector.

    2. B005ZJF

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

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


    1. Connect the connector.

    2. B005XOR

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

  47. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. B005ZI2

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

  48. 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.

  49. INSTALL DECK FLOOR BOX RH

    Click here

  50. INSTALL REAR DECK FLOOR BOX

    Click here

  51. INSTALL NO. 1 DECK BOARD

    Click here

  52. INSTALL NO. 2 DECK BOARD

    Click here

  53. INSTALL DECK BOARD ASSEMBLY

    Click here

  54. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here

  55. INSPECT POWER WINDOW OPERATION

    Click here