DOOR / HATCH FRONT DOOR REASSEMBLY

Hide Display 1. PRECAUTION (w/ Power Window)

NOTICE:: After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.; Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

Hide Display 2. REPAIR INSTRUCTION

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE(for Front Door)>INSTALLATION

Hide Display 75921C 3.INSTALL NO. 1 BLACK OUT TAPE

HINT:: Use the same procedure as for the LH side.; Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE(for Front Door)>INSTALLATION

Hide Display 75755C 4.INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

HINT:: Use the same procedure as for the LH side.; Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR WINDOW FRAME MOULDING>INSTALLATION

Hide Display 75710 5.INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

HINT:: Use the same procedure as for the LH side.; Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR BELT MOULDING>INSTALLATION

Hide Display 67837K 6.INSTALL FRONT DOOR VENT SEAL

a.

Install the front door vent seal.

Hide Display 67001A 7.INSTALL FRONT DOOR PANEL CUSHION

a.

Engage the 2 claws to install 2 new front door panel cushions.

Hide Display 75792 8.INSTALL DOOR WINDOW FRAME MOULDING CLIP

a.

Engage the 2 claws to install a new door window frame moulding clip.

Hide Display 67663D 9.INSTALL DOOR FRAME GARNISH

a.

Engage the clip to install a new door frame garnish.

Hide Display 67861 10.INSTALL FRONT DOOR WEATHERSTRIP

a.

Engage the 16 clips and install the front door weatherstrip.

Hide Display 68610 11.INSTALL FRONT DOOR CHECK ASSEMBLY

a.

Apply MP grease to the sliding areas of the front door check assembly.

b.

Clean the bolt hole on the vehicle body.

c.

Clean the bolt threads of the bolt.

d.

Apply adhesive to the threads of the bolt (A).

Adhesive:: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

e.

0,0 0,0 false

	Bolt (A)
	Bolt (B)

Install the front door check assembly with the 3 bolts.

Torque:: Bolt (A) : 30 N*m (306 kgf*cm, 22 ft.*lbf); Bolt (B) : 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Hide Display 69311A 12.INSTALL FRONT DOOR LOCK OPEN ROD

a.

0.24,0.927 0.396,1.125 0.156,0.198 10 true 1 1.302,0.385 1.458,0.583 0.156,0.198 10 true 2

Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

Hide Display 69201A 13.INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

a.

Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.

b.

0.135,0.167 0.427,0.438 0.292,0.271 12 true *A 0.177,2.49 0.479,2.708 0.302,0.219 12 true *B

*A	Outside
*B	Inside

Engage the claw.

c.

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)

d.

w/ Smart Entry and Start System:

i.

Engage the 3 clamps.

Hide Display 69750C 14.INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

a.

Install the front door inside locking cable assembly as shown in the illustration.

Hide Display 69710B 15.INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

a.

Install the front door lock remote control cable assembly as shown in the illustration.

Hide Display 69035A 16.INSTALL FRONT DOOR LOCK COVER SUB-ASSEMBLY

a.

Engage the 2 claws.

b.

Engage the 2 claws and install the front door lock cover sub-assembly as shown in the illustration.

Hide Display 69310 17.INSTALL FRONT DOOR LOCK ASSEMBLY

NOTICE:: ·

When reusing a removed front door lock 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 assembly.

a.

Apply MP grease to the sliding parts of the front door lock assembly.

b.

When reusing the front door lock assembly:

i.

Install a new door lock wiring harness seal to the front door lock assembly.

c.

0.448,2.865 0.604,2.708 true 0.365,2.885 0.625,3.094 0.26,0.208 10 true *1

*1	Front Door Lock Open Rod

Connect the front door lock open rod to the front door lock assembly.

HINT:: Make sure that the front door lock open rod is securely connected to the front door lock assembly.

d.

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

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

e.

Connect the connector.

Hide Display 69242E 18.INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

a.

Engage the 2 claws to install the front door rear outside handle pad.

Hide Display 69241H 19.INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

a.

Engage the 3 claws to install the front door front outside handle pad.

Hide Display 69210 20.INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

a.

Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.

b.

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.

c.

w/ Smart Entry and Start System:

i.

Connect the connector.

ii.

Engage the 2 claws.

Hide Display 69217E 21.INSTALL FRONT DOOR OUTSIDE HANDLE COVER RH (for Driver Side)

a.

Engage the 2 guides and claw to install the front door outside handle cover RH to the lock cylinder assembly as shown in the illustration.

Hide Display 69217F 22.INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (for Front Passenger Side)

a.

w/o Lock Cylinder:

i.

Using a T30 "TORX" socket wrench, install the front door outside handle cover LH with the screw.

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

ii.

Install the hole plug.

b.

w/ Lock Cylinder:

HINT:: Use the same procedures as for the driver side.

Hide Display 23.INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)

a.

Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw.

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

b.

Install the hole plug.

Hide Display 24.INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Front Passenger Side)

a.

w/ Lock Cylinder:

HINT:: Use the same procedures as for the driver side.

Hide Display 67403F 25.INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

a.

Engage the guide.

b.

Install the front door rear lower frame sub-assembly with the bolt.

Torque:: 6.1 N*m (62 kgf*cm, 54 in.*lbf)

Hide Display 68141C 26.INSTALL FRONT DOOR GLASS RUN

a.

Install the front door glass run.

Hide Display 69820 27.INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY (w/o Power Window)

a.

Apply MP grease to the sliding parts of the front door window regulator assembly.

b.

0.354,1.646 0.51,1.844 0.156,0.198 10 true 1 0.24,0.625 0.396,0.823 0.156,0.198 10 true 2 0.094,1.396 0.25,1.594 0.156,0.198 10 true 3 1.271,0.302 1.427,0.5 0.156,0.198 10 true 4 2.281,0.438 2.438,0.635 0.156,0.198 10 true 5

Install the front door window regulator assembly with the 5 bolts.

HINT:: Tighten the bolts in the order shown in the illustration.

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

Hide Display 85710E 28.INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY (w/ Power Window)

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

a.

Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws to front door window regulator sub-assembly.

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

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

Hide Display 29.INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY (w/ Power Window)

a.

Apply MP grease to the sliding parts of the front door window regulator assembly.

b.

Temporarily install the temporary bolt to the front door window regulator assembly.

c.

1.417,0.885 1.719,0.594 true 1.719,0.438 1.917,0.635 0.198,0.198 10 true *a 0.604,0.208 0.76,0.406 0.156,0.198 10 true 2 0.917,1.542 1.073,1.74 0.156,0.198 10 true 1 0.583,1.542 0.74,1.74 0.156,0.198 10 true 3 1.906,0.458 2.104,0.656 0.198,0.198 10 true 4 1.76,0.781 1.958,0.979 0.198,0.198 10 true 5 2.385,0.896 2.583,1.094 0.198,0.198 10 true 6

*a	Temporary Bolt

Temporarily install the front door window regulator assembly with the 5 bolts.

d.

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)

e.

Connect the connector.

Hide Display 68101 30.INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

a.

w/ Power Window:

i.

Connect the cable to the negative (-) battery terminal.

b.

for Driver Side with Power Window:

i.

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.

c.

for Front Passenger Side with Power Window:

i.

Connect the power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

d.

w/ Power Window:

i.

Disconnect the cable from the negative (-) battery terminal.

e.

for Driver Side with Power Window:

i.

Disconnect the power window regulator master switch assembly.

f.

for Front Passenger Side with Power Window:

i.

Disconnect the power window regulator switch assembly.

g.

w/o Power Window:

i.

Temporarily install the front door window regulator handle assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

ii.

Remove the front door window regulator handle assembly.

h.

0.844,0.26 1.063,0.479 0.219,0.219 10 true 1 2.969,0.208 3.188,0.427 0.219,0.219 10 true 2

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.

i.

Install the front door glass sub-assembly with the 2 bolts.

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

Hide Display 67831 31.INSTALL FRONT DOOR SERVICE HOLE COVER

a.

Apply new butyl tape to the front door panel.

b.

0.292,0.271 0.375,0.375 false 0.427,1.99 0.531,2.01 true 2.906,0.573 3.115,0.438 true 0.125,0.135 0.323,0.333 0.198,0.198 10 false *a 2.75,0.521 2.948,0.719 0.198,0.198 10 false *a 0.583,1.948 0.781,2.146 0.198,0.198 10 false *a

*a	Reference Point

Pass the front door lock remote control cable assembly, front door inside locking cable assembly and each connector through a new front door service hole cover.

c.

Install the front door service hole cover according to the reference points on the front door panel.

NOTICE:: Securely install the front door service hole cover preventing wrinkles and air bubbles.

Hide Display 32.INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

Click hereVehicle Exterior>MIRROR (EXT)>OUTER REAR VIEW MIRROR>INSTALLATION

Hide Display 68171B 33.INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

a.

Engage the 8 claws to install the front door inner glass weatherstrip as shown in the illustration.

Hide Display 69205 34.INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

a.

Engage the 4 guides to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

Hide Display 67601 35.INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

a.

0.365,1.063 0.635,1.385 false 0.74,1.594 0.688,1.906 true 0.198,0.938 0.51,1.135 0.313,0.198 10 false *1 0.604,1.917 0.917,2.115 0.313,0.198 10 false *2

*1	Front Door Inside Locking Cable Assembly
*2	Front Door Lock Remote Control Cable Assembly

Connect the front door lock remote control cable assembly and front door inside locking cable assembly.

b.

Engage the 8 clips and install the front door trim board sub-assembly as shown in the illustration.

c.

Install the 3 screws.

d.

Engage the claw and close the cover.

Hide Display 67491A 36.INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

a.

Engage the 2 guides and clip to install the front door lower frame bracket garnish.

Hide Display 69272 37.INSTALL FRONT DOOR REGULATOR INSIDE HANDLE PLATE (w/o Power Window)

a.

2.594,0.573 2.906,0.771 0.313,0.198 10 false *a

*a	Inside of vehicle

Install the front door regulator inside handle plate.

Hide Display 69260 38.INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)

a.

Temporarily install the front door window regulator handle assembly.

b.

Fully close the front door window.

c.

Remove the front door window regulator handle assembly.

d.

Install the front door window regulator handle shaft snap ring to the front door window regulator handle assembly.

e.

1.323,0.115 1.479,0.313 0.156,0.198 10 false A

Install the front door window regulator handle assembly with front door window regulator handle shaft snap ring at the angle shown in the illustration.

Area	Measurement
A	25° to 35°

Hide Display 39.INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side with Power Window)

a.

Connect the connector.

b.

Engage the 4 guides, 8 claws and clip to install the power window regulator master switch assembly with front door armrest base panel.

Hide Display 40.INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side with Power Window)

a.

Connect the connector.

b.

Engage the 5 guides, 8 claws and clip to install the power window regulator switch assembly with front door armrest base panel.

Hide Display 74210 41.INSTALL FRONT ARMREST ASSEMBLY

a.

Engage the 5 claws and 2 clips to install the front armrest assembly.

Hide Display 74645A 42.INSTALL DOOR ASSIST GRIP COVER

a.

Engage the 10 claws to install the door assist grip cover.

Hide Display 43.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/ Power Window)

NOTICE:: When disconnecting the cable, some systems need to be initialized after the cable is reconnected.; Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION

Hide Display 44.INITIALIZE POWER WINDOW CONTROL SYSTEM (w/ Power Window)

Click hereVehicle Exterior>WINDOW / GLASS>POWER WINDOW CONTROL SYSTEM>INITIALIZATION

Hide Display 45.INSPECT POWER WINDOW OPERATION (w/ Power Window)

Click hereVehicle Exterior>WINDOW / GLASS>POWER WINDOW CONTROL SYSTEM>OPERATION CHECK

CAUTION / NOTICE / HINT

PROCEDURE