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Home >> Toyota >> 2016 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 122 ((Door / Hatch) (Service Information) (Hybrid) (2 Of 2)) >> Front Door >> Reassembly [02/2014 - 11/2015] >> Procedure

Reassembly [02/2014 - 11/2015]: Procedure

WARNING: This page is about a different variant/trim than selected.
  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.

    Refer to PRECAUTION [02/2014 - 11/2016]

  2. INSTALL FRONT DOOR UPPER OUTSIDE MOULDING PAD 

    Refer to PROCEDURE - Step 1

  3. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. REPAIR INSTRUCTION 

    Refer to PROCEDURE - Step 1

  5. INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 2

  6. INSTALL FRONT DOOR UPPER INNER BLACK OUT TAPE 

    Refer to PROCEDURE - Step 3

  7. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 1

  8. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 2

  9. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 1

  10. INSTALL FRONT DOOR VENT SEAL 
    1. Clean the front door panel.
    2. Install a new front door vent seal as shown in the illustration.
      GTY445242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
  11. INSTALL FRONT DOOR PANEL PROTECTOR 
    1. Install the front door panel protector.
      GTY424411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT DOOR PANEL CUSHION 
    1. Engage the 2 claws to install 2 new front door panel cushions.
      GTY424413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL DOOR FRAME GARNISH 
    1. Engage the 3 claws to install the door frame garnish.
      GTY450534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION 
    1. Clean the front door panel.
    2. Engage the 2 guides.
      GTY452069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
    3. Install a new front door No. 2 stiffener cushion with the 2 bolts.
  15. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 20 clips to install the front door weatherstrip.
      GTY424414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Apply MP grease to the sliding parts of the front door check assembly.
    2. Clean the bolt hole on the vehicle body.
    3. Clean the bolt threads of the bolt.
    4. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the front door check assembly with the 2 nuts and bolt.
      GTY439288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Bolt 

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

      Nut 

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

  17. INSTALL FRONT DOOR LOCK OPEN ROD 
    1. Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.
      GTY437392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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. Engage the claw.
      GTY444371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Outside
      *B Inside
    3. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

    4. Engage the 3 clamps.
      GTY429921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the front door inside locking cable assembly as shown in the illustration.
      GTY429923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the front door lock remote control cable assembly as shown in the illustration.
      GTY429917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 2 claws as shown in the illustration.
      GTY429919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY 
    NOTE:
    • When reusing a removed front door lock with motor 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 with motor assembly.
    1. Apply MP grease to the sliding parts of the front door lock with motor assembly.
    2. When reusing the front door lock with motor assembly:
      1. Install a new door lock wiring harness seal to the front door lock with motor assembly.
        GTY429922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the front door lock open rod to the front door lock with motor assembly.
      GTY431745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Lock Open Rod

      HINT: 

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

    4. Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws.

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

    5. Connect the connector.
  22. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the front door rear outside handle pad.
      GTY429913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the front door front outside handle pad.
      GTY429914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.
      GTY429911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame sub-assembly, then slide the front door outside handle assembly toward the front of the vehicle to install it.
    3. Connect the connector.
      GTY451726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 2 claws.
  25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) 
    1. Engage the 2 guides and claw to install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.
      GTY430003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.
      GTY429905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the hole plug.
      GTY430005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw.
      GTY451749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the hole plug.
      GTY430006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide.
      GTY430008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front door rear lower frame sub-assembly with the bolt.

      Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 

  29. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide.
      GTY451750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front door front lower frame sub-assembly with the 2 bolts.

      Torque: 6.2 N*m (63 kgf*cm, 55 in.*lbf) 

    3. Connect the wire harness with the 2 bolts.
      GTY430007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.6 N*m (77 kgf*cm, 67 in.*lbf) 

  30. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      GTY430009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    NOTE:

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

    1. Using a T25 "TORX" socket wrench, install the power window regulator motor assembly with the 3 screws.
      GTY430010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      When replacing a power window regulator motor assembly, a new power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  32. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the front door window regulator assembly.
    2. Temporary install the temporary bolt to the front door window regulator assembly.
    3. Temporarily install the front door window regulator assembly with the 5 bolts.
      GTY434583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporary Bolt
    4. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly.

      HINT: 

      Tighten the bolts in the order shown in the illustration.

      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. for Driver Side:
      1. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
      2. Disconnect the power window regulator master switch assembly.
    3. for Front Passenger Side:
      1. Connect the power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
      2. Disconnect the power window regulator switch assembly.
    4. Disconnect the cable from the negative (-) auxiliary battery terminal.
    5. 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.
      GTY439798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the front door glass sub-assembly with the 2 bolts.
      GTY429967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    7. Install the grommet.
      GTY429966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Apply new butyl tape to the front door panel.
    2. Pass the front door lock remote control cable assembly and front door inside locking cable assembly through a new front door service hole cover.
      GTY423277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point
    3. Install the new 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 NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  36. INSTALL DOOR SIDE AIR BAG SENSOR 

    Refer to PROCEDURE - Step 1

  37. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER 

    Refer to PROCEDURE - Step 1

  38. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) 

    Refer to PROCEDURE - Step 1

  39. INSTALL SEAT MEMORY SWITCH (w/ Memory) 

    Refer to PROCEDURE - Step 1

  40. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 7 claws to install the front door inner glass weatherstrip as shown in the illustration.
      GTY451739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the guide and 2 claws to install the front door inside handle sub-assembly to the front door trim board sub-assembly.
      GTY429978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the front door lock remote control cable assembly and front door inside locking cable assembly.
      GTY445883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
    2. w/ Memory:
      1. Connect the connector.
    3. w/ Illumination:
      1. Connect the connector.
    4. Engage the 10 clips to install the front door trim board sub-assembly as shown in the illustration.
      GTY429975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 3 screws.
      GTY429973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the claw to close the cover.
      GTY429972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 2

  44. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. Connect each connector.
    2. Engage the 2 guides, 2 clips and 4 claws to install the power window regulator master switch assembly with front door upper armrest base panel.
      GTY429985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side) 
    1. Connect each connector.
    2. Engage the 2 guides, 2 clips and 4 claws to install the power window regulator switch assembly with front door upper armrest base panel.
      GTY429983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws to install the front door inside handle bezel plug.
      GTY429981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Engage the guide and 2 clips to install the front door lower frame bracket garnish.
      GTY429986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [02/2014 - 11/2016]

  49. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 71

  50. INSTALL DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 72

  51. INITIALIZE POWER WINDOW CONTROL SYSTEM 
  52. INSPECT POWER WINDOW OPERATION 
  53. INSPECT SRS WARNING LIGHT 

    Refer to DIAGNOSIS SYSTEM [02/2014 - ]

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