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Front Door: Reassembly

  1. REPAIR INSTRUCTION  (See INSTALLATION )
  2. INSTALL INNER REAR BLACK OUT FRONT DOOR TAPE  (See INSTALLATION )
  3. INSTALL INNER UPPER BLACK OUT FRONT DOOR TAPE  (See INSTALLATION )
  4. INSTALL NO. 1 BLACK OUT TAPE  (See INSTALLATION )
  5. INSTALL FRONT DOOR OUTSIDE MOLDING SUB-ASSEMBLY  (See INSTALLATION )
  6. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 8 clips and claw, and install the front door weatherstrip.
      Fig 1: Identifying Front Door Weatherstrip Clips & Claw
      G05422138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DOOR BELT MOLDING ASSEMBLY  (See INSTALLATION )
  8. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION 
    1. Engage the 2 guides and install the front door No. 2 stiffener cushion with the 2 bolts.
      Fig 2: Identifying Guides & Front Door No. 2 Stiffener Cushion With Bolts
      G05422137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL DOOR FRAME GARNISH 
    1. Engage a new clip and install the door frame garnish.
      Fig 3: Identifying Door Frame Garnish Clip
      G05422136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 17 clips and install the front door weatherstrip.
      Fig 4: Identifying Front Door Weatherstrip Clips
      G05422135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Install the front door check assembly with the bolt and 2 nuts.

      Torque: Bolt 

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

      Nut 

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

      Fig 5: Identifying Front Door Check Assembly Bolt & Nuts
      G05422134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System) 
    1. Install the door electrical key oscillator with the screw.
      Fig 6: Identifying Door Electrical Key Oscillator Screw
      G05422147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT DOOR LOCK OPEN ROD 
    1. Install the front door lock open rod as shown below.
      Fig 7: Identifying Front Door Lock Open Rod
      G05422148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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 2 claws 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 8: Identifying Front Door Outside Handle Frame Sub-Assembly Claws & Screw (Without Smart Key System)
      G05422149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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 2 claws 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 9: Identifying Front Door Outside Handle Frame Sub-Assembly Claws & Screw (With Smart Key System)
      G05422150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the clamp.
    5. Connect the connector.
  16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the front door inside locking cable assembly.
      Fig 10: Identifying Front Door Inside Locking Cable Assembly
      G05420279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 claws.
      Fig 11: Identifying Claws
      G05420278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the front door lock remote control cable assembly.
      Fig 12: Identifying Front Door Lock Remote Control Cable Assembly
      G05420277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 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.
    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) 

      Fig 13: Identifying Front Door Lock Assembly Screws
      G05420286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the front door rear outside handle pad.
      Fig 14: Identifying Front Door Rear Outside Handle Pad Claws
      G05422125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the front door front outside handle pad.
      Fig 15: Identifying Front Door Front Outside Handle Pad Claws
      G05422124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. 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 16: Identifying Front Door Outside Handle Assembly
      G05422157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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 17: Identifying Front Door Outside Handle Assembly
      G05420354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
      Fig 18: Connecting Connector
      G05420350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) 
    1. Engage the 2 claws to install the front door outside handle cover to the front door lock cylinder.
      Fig 19: Identifying Front Door Outside Handle Cover Claws
      G05422160Courtesy 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 20: Identifying Front Door Lock Cylinder
      G05422161Courtesy 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) 

    4. Install the hole plug.
      Fig 21: Identifying Hole Plug
      G05422118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. 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 22: Identifying Front Door Outside Handle Cover & Front Door Lock Key Cylinder
      G05422120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the hole plug.
  25. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Install the front door rear lower frame sub-assembly with the bolt.
      Fig 23: Identifying Front Door Rear Lower Frame Sub-Assembly Bolt
      G05422164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      Fig 24: Identifying Front Door Glass Run
      G05422116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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 uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

      Fig 25: Identifying Front Power Window Regulator Motor Sub-Assembly Screws
      G05421172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 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 below to install the front window regulator.

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

      Fig 26: Identifying Front Window Regulator Bolts
      G05422167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. 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 shown below.
      Fig 27: Inserting Front Door Glass Sub-Assembly Into Front Door Panel
      G05422168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front door glass sub-assembly with the 2 bolts.

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

      Fig 28: Identifying Front Door Glass Sub-Assembly Bolts
      G05422112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the hole plug.
  30. 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 the locking cable through a new front door service hole cover.
      Fig 29: Identifying Front Door Glass Sub-Assembly
      G05422111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 avoiding wrinkles and air bubbles.
      Fig 30: Identifying Front Door Service Hole Cover
      G05422171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect each connector.
    5. Engage the 2 clamps.
      Fig 31: Identifying Front Door Service Hole Cover Clamps
      G05422110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER  (See INSTALLATION )
  32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY  (See INSTALLATION )
  33. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Install the front door inner glass weatherstrip.
      Fig 32: Identifying Front Door Inner Glass Weatherstrip
      G05422109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FRONT DOOR WIRE (for Driver Side) 
    1. Engage the 3 clamps and install the front door wire.
      Fig 33: Identifying Front Door Wire Clamps
      G05422108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 2 claws.
    2. Install the 2 screws and install the front door inside handle sub-assembly.
      Fig 34: Identifying Front Door Inside Handle Sub-Assembly Claws
      G05422107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the connector.
    2. Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle sub-assembly.
      Fig 35: Identifying Front Door Lock Remote Control Cable & Front Door Inside Locking Cable
      G05422176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 2 clamps.
    4. Engage the front door trim board with the 5 claws on the front door inner glass weatherstrip.
      Fig 36: Identifying Front Door Trim Board Sub-Assembly Claws
      G05422105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the 9 clips.
    6. Install the 2 screws < B >.
    7. Install the screw < A > and front door trim board to the front door panel.

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

      Fig 37: Identifying Front Door Trim Board Screws
      G05422178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL COURTESY LIGHT ASSEMBLY 
    1. Connect the connector.
    2. Engage the claw and install the courtesy light assembly.
      Fig 38: Identifying Courtesy Light Assembly Claw
      G05422179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL ASSIST GRIP COVER 
    1. Engage the 4 claws and install the assist grip cover.
      Fig 39: Identifying Assist Grip Cover & Claws
      G05422180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) 
    1. Install the power window regulator master switch assembly with the 3 screws.
      Fig 40: Identifying Power Window Regulator Master Switch Assembly Screws
      G05420257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) 
    1. Engage the 2 claws and install the door control switch assembly.
      Fig 41: Identifying Door Control Switch Assembly Claws
      G05422101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) 
    1. Engage the 2 claws and install the power window regulator switch assembly.
      Fig 42: Identifying Power Window Regulator Switch Assembly Claws
      G05422100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL FRONT ARMREST UPPER BASE PANEL 
    1. Connect the connector.
    2. Engage the 7 claws and clip and install the front armrest upper base panel.
      Fig 43: Identifying Front Armrest Upper Base Panel Claws & Clip
      G05422184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws and install the front door inside handle bezel plug.
      Fig 44: Identifying Front Door Inside Handle Bezel Plug Claws
      G05422185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Engage the clip and claw, and install the front door lower frame bracket garnish.
      2. Fig 45: Identifying Front Door Lower Frame Bracket Garnish Claw & Clip
      G05422096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. CONNECT NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  46. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) 

    (See INITIALIZATION )

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