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Front Door: Reassembly

  1. REPAIR INSTRUCTION  (See INSTALLATION )
  2. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE  (See INSTALLATION )
  3. INSTALL FRONT DOOR STRIPE  (See INSTALLATION )
  4. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING  (See INSTALLATION )
  5. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING  (See INSTALLATION )
  6. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY  (See INSTALLATION )
  7. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 19 clips and install the front door weatherstrip.
      Fig 1: Identifying Front Door Weatherstrip Clips
      G04981698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DOOR CHECK ASSEMBLY (for TMC Made) 
    1. Install the front door check assembly with the 3 bolts.

      Torque: 

      Bolt (A) 

      26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Bolt (B) 

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

      Fig 2: Identifying Front Door Check Assembly Bolts
      G04981703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT DOOR CHECK ASSEMBLY (for TMMK Made) 
    1. Install the front door check assembly with the bolt and 2 nuts.

      Torque: 

      Bolt 

      26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Nut 

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

      Fig 3: Identifying Front Door Check Assembly Bolt And Nuts
      G04981697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System) 
    1. Install the door electrical key oscillator with the screw.
      Fig 4: Locating Door Electrical Key Oscillator Screw
      G04981705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System) 
    1. Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.
    2. Engage the claw to install the front door outside handle frame sub-assembly.
    3. Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.

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

      Fig 5: Identifying Front Door Outside Handle Frame Sub-Assembly
      G04981706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System) 
    1. Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.
    2. Engage the claw to install the front door outside handle frame sub-assembly.
    3. Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.

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

    4. Engage the 2 clamps.
    5. Connect the connector.
      Fig 6: Identifying Front Door Outside Handle Frame Sub-Assembly
      G04981707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the front door inside locking cable assembly.
      Fig 7: Identifying Front Door Inside Locking Cable Assembly
      G04981692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 claws.
      Fig 8: Identifying Front Door Inside Locking Cable Assembly Claws
      G04980476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the front door lock remote control cable assembly.
      Fig 9: Identifying Front Door Lock Remote Control Cable Assembly
      G04981690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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 to the connection. 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. Install a new door lock wiring harness seal to the front door lock assembly.
    3. Insert the front door lock open rod to the front door lock assembly, and set it to the front door outside handle frame.
      Fig 10: Identifying Front Door Lock Open Rod To Front Door Lock Assembly
      G04981711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.
    5. Using a "TORX" socket wrench (T30), install the front door lock assembly with the 3 screws.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    6. Connect the connector.
  16. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the front door rear outside handle pad.
      Fig 11: Identifying Front Door Rear Outside Handle Pad Claws
      G04981688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the front door front outside handle pad.
      Fig 12: Identifying Front Door Front Outside Handle Pad Claws
      G04981687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System) 
    1. 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. Next, slide the front door outside handle assembly toward the front of the vehicle to install it.
      Fig 13: Locating Front Door Outside Handle Assembly (w/o Smart Key System)
      G04981714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System) 
    1. 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. Next, slide the front door outside handle assembly toward the front of the vehicle to install it.
      Fig 14: Locating Front Door Outside Handle Assembly
      G04980507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
      Fig 15: Locating Front Door Outside Handle Assembly Connector
      G04980504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER 
    1. Engage the 2 claws to install the front door outside handle cover to the front door lock cylinder.
      Fig 16: Identifying Front Door Outside Handle Cover Claws
      G04981717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front door lock cylinder.

      HINT:

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

      Fig 17: Identifying Front Door Lock Cylinder
      G04981718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a "TORX" socket wrench (T30), install the front door lock cylinder with the screw.

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

      Fig 18: Installing Front Door Lock Cylinder Screw
      G04981682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the hole plug.
  21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Install the front door rear lower frame sub-assembly with the bolt.
      Fig 19: Identifying Front Door Rear Lower Frame Sub-Assembly Bolt
      G04981720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Install the front door front lower frame sub-assembly with the 2 bolts.
      Fig 20: Identifying Front Door Front Lower Frame Sub-Assembly Bolts
      G04981721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL DOOR FRAME GARNISH 
    1. Engage the clip and install a new door frame garnish.
      Fig 21: Identifying Door Frame Garnish Clip
      G04981679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      Fig 22: Identifying Front Door Glass Run
      G04981678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION 
    1. Engage the 2 claws and install a new front No. 1 door stiffener cushion with double-sided tape.
      Fig 23: Identifying Front No. 1 Door Stiffener Cushion With Double-Sided Tape And Claws
      G04981677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.
    1. Using a "TORX" driver (T25), install the front power window regulator motor sub-assembly with the 3 screws.

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

      HINT:

      A new front window regulator adopts a self-tapping method. The installation position of the regulator will be threaded when the self-tapping screw is inserted.

      Fig 24: Identifying Front Power Window Regulator Motor Sub-Assembly Screws
      G04981725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts of the front door window regulator sub-assembly.
    2. Install the temporary bolt to the front door window regulator sub-assembly.
    3. Temporarily install the window regulator.
    4. Tighten the 6 bolts in the order shown in the illustration to install the front window regulator.

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

      Fig 25: Tightening Front Door Window Regulator Sub-Assembly Bolts In Order
      G04981726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated in the order of the arrows in the illustration.
      Fig 26: Inserting Front Door Glass Sub-Assembly Into Front Door Panel
      G04981727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front door glass sub-assembly with the 2 bolts.

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

      Fig 27: Identifying Front Door Glass Sub-Assembly Bolts
      G04981673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Apply butyl tape to the front door panel.
    2. Pass the front door lock remote control cable and rear door inside locking cable through a new front door service hole cover.
    3. Install the new service hole cover.
      NOTE: Securely install the front door service hole cover avoiding wrinkles and air bubbles.
    4. Connect each connector and each clamp.
      Fig 28: Identifying Front Door Service Hole Cover Clamp
      G04981729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY  (See INSTALLATION )
  31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY  (See INSTALLATION )
  32. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 4 claws and install the front door inner glass weatherstrip.
      Fig 29: Identifying Front Door Inner Glass Weatherstrip Claws
      G04981730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL FRONT ARMREST BASE PANEL UPPER 
    1. Engage the 4 claws and install the front armrest base panel upper.
    2. Install the 7 screws.
      Fig 30: Locating Front Armrest Base Panel Upper Claws And Screws
      G04981670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FRONT DOOR WIRE (for Driver Side) 
    1. Install the front door wire with the 2 screws.
    2. Engage the clamp.
      Fig 31: Locating Front Door Wire Screws And Clamp
      G04981668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY 
    1. Connect the connector.
    2. Install the power window regulator master switch assembly with the 3 screws.
      Fig 32: Locating Power Window Regulator Master Switch Assembly Screws
      G04980463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle sub-assembly.
      Fig 33: Locating Front Door Lock Remote Control Cable And Front Door Inside Cable
      G04981734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 claws and install the front door inside handle sub-assembly.
      Fig 34: Identifying Front Door Inside Handle Sub-Assembly Claws
      G04981666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect each connector.
    2. Engage the front door trim board with the 4 clips of the front door inner glass weatherstrip.
      Fig 35: Identifying Front Door Trim Board Clips
      G04981736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 9 clips and install the front door trim board to the front door panel.
    4. Install the 3 screws and clip (A).
      Fig 36: Identifying Front Door Trim Board Screws And Clip
      G04981737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL COURTESY LIGHT ASSEMBLY 
    1. Connect the connector.
    2. Engage the claw and install the courtesy light assembly.
      Fig 37: Identifying Courtesy Light Assembly Claw
      G04981738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL ASSIST GRIP COVER 
    1. Engage the 6 claws and install the assist grip cover.
      Fig 38: Identifying Assist Grip Cover Claws
      G04981739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws and install the front door inside handle bezel plug.
      Fig 39: Identifying Front Door Inside Handle Bezel Plug Claws
      G04981740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Engage the 2 clips and install the front door lower frame bracket garnish.
      Fig 40: Identifying Front Door Lower Frame Bracket Garnish Clips
      G04981660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    (See INITIALIZATION )

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