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Home >> Toyota >> 2021 >> Avalon TRD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (1 Of 2) >> Front Door >> Reassembly [04/2018 - 08/2020] >> Procedure

Reassembly [04/2018 - 08/2020]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch (for Gasoline Model) or power switch (for HV Model) 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 [04/2018 -]

  2. REPAIR INSTRUCTION 

    Refer to PROCEDURE - Step 2

  3. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP 
    1. Install the front door No. 3 weatherstrip with the 4 clips.
      GTY868478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front door panel sub-assembly with the 4 bolts.

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

      NOTE:

      To prevent damage, when installing the front door panel sub-assembly, make sure that there are enough people available to hold it securely.

      GTY844034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brush, apply anti-rust coating to the front door hinge assembly as shown in the illustration.
      GTY850281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Section
      *1 Front Door Upper Hinge Assembly
      *2 Front Door Lower Hinge Assembly
      *a Front Door Hinge Assembly
      *b Anti-rust Coating
    4. Connect the connector.
    5. Engage the 4 claws to connect the grommet as shown in the illustration.
      NOTE:

      Install the grommet with the arrow facing up.

      GTY928681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Reference Point
  4. INSTALL FRONT DOOR SILENCER PAD 
    1. Clean the front door panel surface.
      1. Remove any remaining butyl tape from the front door panel.
      2. Wipe off any tape adhesive residue with cleaner.
    2. Remove the release paper from 2 new front door silencer pads.

      HINT: 

      After removing the release paper, keep the exposed adhesive free from foreign matter.

    3. Install the 2 front door silencer pads as shown in the illustration.
      GTY843010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      INSTALLATION POSITION

      Area Measurement Area Measurement
      a 46.4 mm (1.83 in.) b 46.4 mm (1.83 in.)
      c 119.5 mm (4.70 in.) d 8.0°
      e 18 mm (0.709 in.) f 9.1 mm (0.358 in.)
      g 99.2 mm (3.91 in.) h 31.8 mm (1.25 in.)
  5. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 1

  6. INSTALL FRONT DOOR REAR OUTSIDE SEAL 
    1. Engage the guide to install the front door rear outside seal.
      GTY868484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE) 

    Refer to PROCEDURE - Step 2

  8. INSTALL NO. 1 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 3

  9. INSTALL NO. 2 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 4

  10. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER 

    Refer to PROCEDURE - Step 1

  11. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 2

  12. INSTALL FRONT DOOR DUST PROOF SEAL 
    1. Engage the claw to install a new front door dust proof seal.
      GTY932850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL DOOR WINDOW FRAME MOULDING CLIP 
    1. Engage the 2 claws to install the door window frame moulding clip.
      GTY868480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 8 clips to install the front door No. 2 weatherstrip.
      GTY932847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT DOOR PANEL CUSHION 
    1. Engage the 4 claws to install 2 new front door panel cushions.
      GTY868470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 23 clips and install the front door weatherstrip.
      GTY868472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL DOOR FRAME GARNISH 
    1. Engage the 3 claws to install the door frame garnish.
      GTY868473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Clean the bolt hole in the vehicle body.
    2. Clean the threads of the bolt.
    3. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the front door check assembly with the 2 nuts and bolt.
      GTY892479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt

      Bolt 

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Nut 

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

  19. 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.
      GTY898895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
  20. 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 guide and claw as shown in the illustration.
      GTY867595Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    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) 

      GTY868466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  22. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 3 guides and claw to install the front door rear outside handle pad.
      GTY868465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the guide and 2 claws to install the front door front outside handle pad.
      GTY868551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Engage the 2 claws.
      GTY868550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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) 

    3. Install the hole plug.
      GTY868547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly with the screw.
      GTY868552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the hole plug.
      GTY932865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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.
      GTY913322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    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. Move the lever as shown in the illustration and engage the 2 claws to secure the front door outside handle assembly.
      GTY880900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engage in this Direction
    4. Engage the 3 clamps.
      GTY868546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the connector.
      GTY868545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the 2 claws as shown in the illustration.
      GTY852453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engage in this Direction
  27. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide as shown in the illustration.
      GTY843395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front door front lower frame sub-assembly with the 2 bolts.
  28. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide as shown in the illustration.
      GTY903839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front door rear lower frame sub-assembly with the 2 bolts.
  29. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      GTY868339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the front door window regulator assembly.
    2. Temporarily install the temporary bolt to the front door window regulator assembly.
    3. Temporarily install the front door window regulator assembly with the 5 bolts.
      Fig 1: Identifying Front Door Window Regulator Assembly Bolts With Tightening Sequence
      GTY935860Courtesy 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.
    6. Engage the 2 claws to install the front door No. 2 service hole cover.
      GTY932818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. for Driver Side:
      1. Connect the multiplex network master switch assembly.
    2. for Front Passenger Side:
      1. Connect the power window regulator switch assembly.
    3. for Gasoline Model:
      1. Connect the cable to the negative (-) battery terminal.
    4. for HV Model:
      1. Connect the cable to the negative (-) auxiliary battery terminal.
    5. for Gasoline Model:
      1. Turn the engine switch on (IG).
    6. for HV Model:
      1. Turn the power switch on (IG).
    7. Move the front door window regulator assembly so that the door glass bolt holes can be seen.
    8. for Gasoline Model:
      1. Turn the engine switch off.
    9. for HV Model:
      1. Turn the power switch off.
    10. for Gasoline Model:
      1. Disconnect the cable from the negative (-) battery terminal.
    11. for HV Model:
      1. Disconnect the cable from the negative (-) auxiliary battery terminal.
    12. for Driver Side:
      1. Disconnect the multiplex network master switch assembly.
    13. for Front Passenger Side:
      1. Disconnect the power window regulator switch assembly.
    14. Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.
      GTY887800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
    15. Install the front door glass sub-assembly with the 2 bolts.
      GTY868336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    16. Install the hole plug.
      GTY868320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL FRONT DOOR VENT SEAL 
    1. Install the front door vent seal as shown in the illustration.
      GTY925379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the clip to connect the front door weatherstrip as shown in the illustration.
      GTY868321Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL FRONT DOOR PANEL PROTECTOR 
    1. Install the front door panel protector as shown in the illustration.
      GTY905862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  34. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 2 guides and install the front door inner glass weatherstrip as shown in the illustration.
      GTY894062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
  35. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Engage the 3 clips to install the front door service hole cover.
      GTY868323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the 4 front door weatherstrip clips and turn them 45 degrees as shown in the illustration to install them.
      GTY868377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 2 clamps.
      GTY868373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FRONT DOOR TRIM BRACKET 
    1. Install the front door trim bracket with the screw.
      GTY868376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL SIDE AIRBAG PRESSURE SENSOR 

    Refer to PROCEDURE - Step 1

  38. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  39. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER 

    Refer to PROCEDURE - Step 1

  40. INSTALL OUTER MIRROR INSTALL HOLE COVER 

    Refer to PROCEDURE - Step 2

  41. INSTALL HOLE PLUG 

    Refer to PROCEDURE - Step 3

  42. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Engage the guide and clip to install the front door lower frame bracket garnish.
      GTY932827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL HOLE PLUG 
    1. Install the 2 hole plugs.
      GTY868379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL PLUG PLATE (w/o Memory) 
    1. Install the 2 plug plates.
      GTY868378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) 

    Refer to PROCEDURE - Step 1

  46. INSTALL FRONT DOOR ORNAMENT 
    1. Engage the 2 guides to install the front door ornament as shown in the illustration.
      GTY911547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  47. INSTALL FRONT DOOR PULL HANDLE 
    1. Engage the guide and 4 claws as shown in the illustration.
      GTY901711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front door pull handle with the 2 screws.
  48. INSTALL FRONT DOOR TRIM COVER 
    1. Engage the 3 guides to install the front door trim cover as shown in the illustration.
      GTY889559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the 2 guides as shown in the illustration.
      GTY865135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    3. Install the front armrest assembly with front door trim cover with the 10 screws.
      GTY867641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL FRONT DOOR TRIM BODY BRACKET 
    1. Install the front door trim body bracket with the 3 screws.
      GTY867637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY 
    1. Temporarily install the front door trim ornament sub-assembly as shown in the illustration.
      GTY844490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front door trim ornament sub-assembly with the 8 screws.
      GTY867638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY (w/ Illumination) 

    Refer to PROCEDURE - Step 1

  52. INSTALL FRONT DOOR INSIDE PANEL PLATE (w/ Seat Memory Switch) 
    1. Engage the 2 claws to install the front door inside panel plate as shown in the illustration.
      GTY915812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  53. INSTALL SEAT MEMORY SWITCH (w/ Seat Memory Switch) 

    Refer to PROCEDURE - Step 1

  54. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 3 claws to install the front door inside handle sub-assembly.
      GTY868366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. w/ Seat Memory Switch:
      GTY850802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/ Seat Memory Switch
      *B w/ Illumination
      1. Connect the connector.
    2. w/ Illumination:
      1. Connect the connector.
    3. Connect the front door lock open lever remote control cable and front door inside lock/unlock knob locking cable to the front door inside handle sub-assembly as shown in the illustration.
      GTY844724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Lock/Unlock Knob Locking Cable
      *2 Front Door Lock Open Lever Remote Control Cable
      Install in this Direction
    4. Engage the guide, 6 claws and 10 clips as shown in the illustration.
      GTY905914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    5. Install the front door trim board sub-assembly with the 3 screws.
      GTY868355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 2

  57. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. Connect the connector.
    2. Engage the 3 claws and 3 clips to install the multiplex network master switch assembly with front door upper armrest base panel as shown in the illustration.
      GTY926529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  58. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side) 
    1. Connect the connector.
    2. Engage the 3 claws to install the power window regulator switch assembly with front door upper armrest base panel as shown in the illustration.
      GTY874844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  59. INSTALL FRONT DOOR TRIM POCKET COVER 
    1. Engage the 2 guides and claw to install the front door trim pocket cover.
      GTY868351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL FRONT DOOR ARMREST COVER SUB-ASSEMBLY 
    1. Engage the 3 claws to install the front door armrest cover sub-assembly.
      GTY868347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. ADJUST FRONT DOOR 

    Refer to ADJUSTMENT [04/2018 - 08/2020] 

  62. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    for A25A-FXS:

    Refer to PROCEDURE - Step 2

    for 2GR-FKS:

    Refer to PROCEDURE - Step 2

  63. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for HV Model) 

    Refer to PROCEDURE - Step 3

  64. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    for Gasoline Model:

    Refer to INITIALIZATION [04/2018 -]

    for HV Model:

    Refer to INITIALIZATION [04/2018 -]

  65. INSPECT POWER WINDOW OPERATION 

    for Gasoline Model:

    Refer to OPERATION CHECK [04/2018 -]

    for HV Model:

    Refer to OPERATION CHECK [04/2018 -]

  66. INSPECT SRS WARNING LIGHT 

    for Gasoline Model:

    Refer to OPERATION CHECK [04/2018 -]

    for HV Model:

    Refer to OPERATION CHECK [04/2018 -]

  67. PERFORM CALIBRATION (w/ Panoramic View Monitor System) 

    for Gasoline Model:

    Refer to CALIBRATION [04/2018 -]

    for HV Model:

    Refer to CALIBRATION [04/2018 -]

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