Front Door: Installation

HINT:

• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (see STANDARD BOLT ).

1. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP LH 
   1. Install the door No. 3 weatherstrip to the door with the 3 clips.
   Fig 1: Identifying Front Door Weatherstrip Clips
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. INSTALL FRONT DOOR PANEL SUB-ASSEMBLY LH 
   1. Install the door panel with the 2 bolts.

      Torque: 32.5 N*m (332 kgf*cm, 24 ft.*lbf) 

3. INSTALL FRONT DOOR WIRE LH 
   1. Connect the connector.
   Fig 2: Identifying Front Door Wire LH
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL FRONT DOOR WEATHERSTRIP LH 
   1. Attach the clips to install the weatherstrip.

      HINT:

      If clips are damaged during installation, replace them.

      Fig 3: Identifying Front Door Weatherstrip Clip

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. 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: 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 bolt.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

   5. Install the cover.
   Fig 4: Identifying Front Door Check Assembly LH
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL FRONT DOOR LOWER FRAME GARNISH PAD LH 
   1. Install the frame garnish pad with the 2 bolts.
   Fig 5: Identifying Front Door Lower Frame Garnish Pad LH Bolts
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (for Front Door) 
   1. Install the door electrical key oscillator to the outside front door handle frame with the screw.
8. INSTALL NO. 2 BACK DOOR WIRE 
   1. Connect the connector.
   2. Attach the 2 clamps to install the wire harness to the frame.
      Fig 6: Identifying No. 2 Back Door Wire

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
   1. Install the lock open rod to the outside handle frame.
   2. Install the frame and tighten the screw.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      NOTE: A cover should be inserted between the screw and the door panel.
   3. Connect the connectors.
      Fig 7: Identifying Front Door Outside Handle Frame Sub-Assembly LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL FRONT DOOR INSIDE LOCKING LH CABLE ASSEMBLY 
    1. Install the front door inside locking cable.
       Fig 8: Identifying Front Door Inside Locking Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH 
    1. Install the front door lock remote control cable.
       Fig 9: Identifying Front Door Lock Remote Control Cable

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. INSTALL FRONT DOOR LOCK ASSEMBLY LH 
    1. w/o Door Closer:
       1. Apply adhesive to the threads of the 3 screws.

          Adhesive:

          Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

       2. Using a T30 "TORX" wrench, install the door lock with the 3 screws.

          Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

       3. Connect the door lock connector.
       Fig 10: Identifying Front Door Lock Assembly (W/O Door Closer)
       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/ Door Closer:
       1. Apply adhesive to the threads of the 5 screws.

          Adhesive: 

          Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

       2. Using a T30 "TORX" wrench, install the door lock with the 3 screws labeled A and 2 screws labeled B.

          Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) for screw A and screw B 

       3. Connect the door lock connector.
          Fig 11: Identifying Front Door Lock Assembly (W/ Door Closer)

          Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
13. INSTALL NO. 2 SEPARATION DOOR STIFFENER CUSHION 
    1. Install the cushion with the 2 bolts.
14. INSTALL FRONT DOOR OUTSIDE HANDLE PAD FRONT 
    1. Attach the 3 claws to install the pad.
       Fig 12: Identifying Front Door Outside Handle Pad Front

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR 
    1. Attach the 2 claws to install the pad.
       Fig 13: Identifying Front Door Outside Handle Pad Rear

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
16. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH 
    1. Pull and hold the bellcrank lever of the frame as shown in the illustration.
    2. Install the handle by pushing it in the direction of the arrow in the illustration.
       NOTE: If the bellcrank lever is not pulled and held when installing the handle, the bellcrank lever will interfere with the handle and become damaged.
       Fig 14: Pulling Bellcrank Lever Of Frame

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a T30 "TORX" socket, install the screw.
    4. Connect the connector.
       Fig 15: Locating Connector With Socket

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
17. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH 
    1. Using a T30 "TORX" socket, install the cover (with the door key cylinder) with the screw.

       Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

    2. Install the hole plug.
    Fig 16: Identifying Front Door Outside Handle Cover LH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
18. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH 
    1. Install the frame with the 2 bolts.

       Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

       Fig 17: Identifying Front Door Rear Frame Sub-Assembly Rear Lower LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
19. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH 
    1. Install the frame with the 2 bolts.

       Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

       Fig 18: Identifying Front Door Lower Frame Sub-Assembly Front Lower LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
20. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 
    1. Apply MP grease to the sliding and rotating areas of the regulator motor.
    2. Using a T25 "TORX" driver, install the motor with the 3 screws.

       Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

       Fig 19: Identifying Front Power Window Regulator Motor Assembly LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
21. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 
    1. Apply MP grease to the sliding and rotating area of the window regulator.
       NOTE: Do not apply grease to the spring of the window regulator.
    2. Loosely install the bolt labeled A onto the window regulator.
    3. Insert the window regulator into the door panel. Use the bolt labeled A to hang the window regulator on the door panel.
    4. Install the window regulator with the 5 bolts and tighten the bolt labeled A.

       Torque: 11.0 N*m (112 kgf*cm, 8 ft.*lbf) 

       NOTE: Be careful not to drop the window regulator as it may become damaged.
    5. Connect the window regulator connector.
    Fig 20: Identifying Front Door Window Regulator Sub-Assembly LH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
22. INSTALL FRONT DOOR BELT MOULDING SUB-ASSEMBLY LH 
    1. Install the belt moulding with the 6 screws.

       HINT:

       Install the screws in the order shown in the illustration.

    2. Tighten the 5 belt line screws indicated by the arrows in the illustration.
       Fig 21: Identifying Belt Line Screws

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install a nose piece to an air riveter or hand riveter. Then insert the mandrel part of a new ø4 mm waterproof rivet into the nose piece.
    4. Using the air riveter or hand riveter, install the rivet shown in the illustration.
       Fig 22: Identifying Rivet

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       HINT:

       The rivet labeled (C) is for fixing the front door belt moulding in place.

       If the rivet cannot be cut, pull it once and cut it.

       NOTE:

       • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
         Fig 23: Precaution For Riveter and Mandrel

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       Fig 24: Precaution For Riveter (1 Of 2)
       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
       • Confirm that the rivet is seated properly against the moulding.
       • Do not tilt the riveter when installing the rivet to the moulding.
       • Do not leave any space between the rivet head and moulding.
       • Do not leave any space between the moulding and door frame. Firmly hold together the 2 items while installing the rivet.
    Fig 25: Precaution For Riveter (2 Of 2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
23. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING LH  (See INSTALLATION )
24. INSTALL FRONT DOOR BELT MOULDING END COVER REAR LH 
    1. Place double-sided tape on the front door weatherstrip as shown in the illustration.
       Fig 26: Identifying Double-Sided Tape On Front Door Weatherstrip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clip and install the front door weatherstrip.
       Fig 27: Identifying Front Door Weatherstrip Clip

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
25. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH  (See INSTALLATION )
26. INSTALL FRONT DOOR GLASS RUN LH 
    1. Install the front door glass run.
27. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH 
    1. 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.
       Fig 28: Inserting Door Glass Into Door Panel

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the door glass to the window regulator with the 2 bolts.

       Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

    3. Install the hole plug.
       Fig 29: Identifying Door Glass To Window Regulator With Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
28. INSTALL FRONT DOOR GLASS WEATHERSTRIP INNER LH 
    1. Install the front door glass weatherstrip inner LH.
    Fig 30: Identifying Front Door Glass Weatherstrip Inner LH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH  (See INSTALLATION )
30. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door.
    2. Install a new service hole cover.

       HINT:

       • When installing the service hole cover, pull the links and connectors through the service hole cover.
       • There should be no wrinkles or folds after attaching the service hole cover.
       • After attaching the service hole cover, check the sealing quality.
31. INSTALL NO. 2 FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door.
    2. Install a new service hole cover.

       HINT:

       • When installing the service hole cover, pull the links and connectors through the service hole cover.
       • There should be no wrinkles or folds after attaching the service hole cover.
       • After attaching the service hole cover, check the sealing quality.
32. INSTALL FRONT DOOR ECU LH 
    1. Install the door ECU to the door panel with the 2 screws.
    2. Connect the 3 connectors.
    Fig 31: Identifying Front Door ECU LH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
33. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY 
    1. Install the speaker to the door panel with the 4 screws.
    2. Connect the connector.
    Fig 32: Identifying Front No. 1 Speaker Assembly Screws
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
34. INSTALL DOOR FRAME GARNISH LH 
    1. Attach the 2 clips to install the garnish.
       Fig 33: Identifying Door Frame Garnish

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
35. INSTALL FRONT DOOR TRIM COVER LH 
    1. Install the screw.
    2. Attach the 5 clips and install the trim cover.
    Fig 34: Identifying Front Door Trim Cover LH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
36. INSTALL INDICATOR LIGHT COVER 
    1. Install the indicator light cover.
37. INSTALL INDICATOR LIGHT BRACKET 
    1. Install the indicator light bracket.
38. INSTALL INDICATOR LIGHT ASSEMBLY 
    1. Install the indicator light assembly with the screw.
    2. Connect the connector.
39. INSTALL SEAT MEMORY SWITCH 
    1. Install the switch to the door trim panel with the 4 claws.
    2. Connect the connector.
       Fig 35: Identifying Seat Memory Switch

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
40. INSTALL HEIGHT ADJUSTABLE ANCHOR SWITCH 
    1. Attach the 2 claws to install the height adjustable anchor switch.
    2. Connect the connector.
       Fig 36: Identifying Height Adjustable Anchor Switch

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
41. INSTALL COURTESY LIGHT ASSEMBLY 
    1. Attach the claw to install the courtesy light to the door trim panel.
    2. Connect the connector.
       Fig 37: Identifying Courtesy Light Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
42. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY LH 
    1. Connect the connector.
    2. Attach the claw to install the light.
    Fig 38: Identifying Front Door Inside Handle Illumination Light Assembly LH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
43. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH 
    1. Connect the connector.
    2. Connect the 2 cables to the inside handle.
       Fig 39: Connecting Cables To Inside Handle

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the front door trim board sub-assembly LH with the 3 screws and 13 clips.
       Fig 40: Identifying Front Door Trim Board Sub-Assembly Screws And Clips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
44. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY 
    1. Connect the connector.
    2. Install the master switch assembly.
       Fig 41: Identifying Master Switch Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
45. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH 
    1. Attach the 3 claws to install the bezel plug.
       Fig 42: Identifying Front Door Inside Handle Bezel Plug LH

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
47. INSTALL COWL TOP VENTILATOR LOUVER RH  (See INSTALLATION )
48. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
       NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
49. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (see DIAGNOSIS SYSTEM ).