FRONT DOOR > REASSEMBLY

for Preparation Click here

NOTICE:

After turning the power 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 here).

1. Engage the front door upper window frame moulding to the door frame.
   

2. Using an air riveter or hand riveter with a nose piece, install the front door upper window frame moulding with 8 new rivets.
   

   HINT:

   If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

   NOTICE:

   
   
   1. Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
      

      Text in Illustration 

      *1	Riveter
      *2	Mandrel
      *a	Incorrect

   
   
   2. Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding.
      

      Text in Illustration 

      *1	Riveter
      *a	Incorrect

   
   
   3. Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.
      

      Text in Illustration 

      *1	Riveter
      *a	Incorrect

HINT:

When installing a new front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light.

NOTICE:

Do not heat the vehicle body or front door rear window frame moulding excessively.

1. Clean the vehicle body surface.
   
   

   1. Using a heat light, heat the vehicle body surface.
      

   2. Remove the double-sided tape from the vehicle body.
      

   3. Wipe off any tape adhesive residue with cleaner.
      

2. Install a new front door rear window frame moulding.
   

   Text in Illustration 

   *1	Double-sided Tape
   *2	Caulking Sponge

   
   

   1. Using a heat light, heat the vehicle body and front door rear window frame moulding.
      

   2. Remove the release paper from the face of the front door rear window frame moulding.
      

      HINT:

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

   3. Install the front door rear window frame moulding with the clip.
      

1. Engage the 7 claws to install the front door belt moulding assembly.
   

HINT:

When installing a new front door front lower frame upper cover, heat the vehicle body using a heat light.

NOTICE:

Do not heat the vehicle body or moulding excessively.

1. Clean the vehicle body surface.
   
   

   1. Using a heat light, heat the vehicle body surface.
      

   2. Remove the double-sided tape from the vehicle body.
      

   3. Wipe off any tape adhesive residue with cleaner.
      

2. Install a new front door front lower frame upper cover.
   
   

   1. Using a heat light, heat the vehicle body and a new front door front lower frame upper cover.
      

   2. Remove the release paper from the front door front lower frame upper cover.
      

      HINT:

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

   3. Engage the 2 clips and install the new front door front lower frame upper cover.
      

1. Clean the vehicle body surface.
   
   

   1. Using a heat light, heat the vehicle body surface.
      

      Heating Temperature 

      Item	Temperature
      Vehicle Body	40 to 60°C (104 to 140°F)

      NOTICE:

      Do not heat the vehicle body excessively.

   2. Wipe off any tape adhesive residue with cleaner.
      

2. Installation temperature
   
   

   1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.
      

      HINT:

      1. The most appropriate temperature for installing the tape is 25°C (77°F).
         
      2. When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases.
         

3. Before installation
   
   

   1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.
      

      HINT:

      Spray water on the shop floor to settle any dust.

4. Key points for handling the tape
   
   

   1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.
      

      NOTICE:

      Do not bend the tape or leave it in high temperature places.

5. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)
   

   NOTICE:

   1. Position the tape accurately to achieve a neat finish and to avoid peeling.
      
   2. The tape cannot be reused because it deforms and will not fit any more after being removed.
      
   
   
   
   
   

   1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 3 to 7 cm (1.18 to 2.76 in.) per second.
      
      

      
      
      
      
      

      Text in Illustration 

      *A	Pressing Forward	*B	Pulling
      *1	Non-padded Side	*2	Padded Side
      *3	Squeegee	*4	Black Out Tape
      *5	Release Paper	-	-
      *a	Side View	-	-

      Reference Measurement 

      Area	Measurement
      A	10 to 20 mm (0.393 to 0.787 in.)
      B	30 to 70 mm (1.18 to 2.76 in.)
      C	40 to 50° (for pressing forward)
      D	30 to 45° (for pulling)

      NOTICE:

      Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

      HINT:

      1. Either angle of the squeegee (pressing forward or pulling) is acceptable.
         
      2. Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.
         

6. Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces)
   
   

   
   
   

   1. If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.
      

      Text in Illustration 

      *1	Squeegee
      *2	Hem
      *a	First
      *b	Second
      *c	Third

      HINT:

      When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

7. Key points for installation of the tape (how to use a squeegee and installation procedure for corners)
   
   

   1. Remove the release paper and apply the tape carefully with your fingers.
      

   2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.
      

8. Check after installation
   
   

   1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.
      

      NOTICE:

      Do not reuse the tape.

1. Refer to the illustration to position the front door rear outside stripe.
   
   

   
   
   
   
   

   Text in Illustration 

   *A	LH Side	*B	RH Side
   *a	Edge of Curved Surface	*b	Square
   *c	Round	-	-

   Standard Measurement 

   Dimension	Measurement
   A	1.5 mm (0.0591 in.)
   B	1.0 mm (0.0394 in.)

2. Remove the release paper and apply the stripe.
   

1. Refer to the illustration to position a new front door outside stripe.
   
   

   
   
   
   
   

   Text in Illustration 

   *A	LH Side	*B	RH Side
   *a	Edge of Curved Surface	*b	Square
   *c	Round	-	-

   Standard Measurement 

   Dimension	Measurement
   A	1.5 mm (0.0591 in.)
   B	1.0 mm (0.0394 in.)

2. Remove the release paper and apply the stripe.
   

1. Install door dust proof seal.
   

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

1. Engage the 8 clips to install the front door No. 2 weatherstrip.
   

1. Engage the 20 clips and install a new front door weatherstrip.
   

   Text in Illustration 

   *1	Double-sided Tape

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

2. Apply adhesive to the threads of the bolt.
   

   Adhesive:

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
   

3. 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 }

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

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

2. Engage the door handle nut and claw.
   

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 }

1. Engage the 5 clamps and install the electrical key wire harness.
   

2. Connect the connector.
   

1. Install the front door inside locking cable assembly.
   

2. Engage the 3 claws.
   

1. Install the front door lock remote control cable assembly.
   

NOTICE:

1. When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
   
2. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
   
3. Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. 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.
   

   Text in Illustration 

   *1	Front Door Lock Open Rod

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

5. 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 }

6. Connect the connector.
   

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

1. Engage the 3 claws and install the front door front outside handle pad.
   

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, then slide the front door outside handle assembly toward the front of the vehicle to install it.
   

3. Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.
   

4. Connect the connector.
   

5. Engage the 2 claws.
   

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

1. 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 }

2. Install the hole plug.
   

1. Install the front door outside handle cover with lock cylinder assembly.
   

   HINT:

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

2. Using a T30 "TORX" socket wrench, install the front door lock cylinder with the screw.
   

   Torque:

   4.0 N*m{ 41 kgf*cm , 35 in.*lbf }

3. Install the hole plug.
   

1. Engage the guide.
   

2. Install the front door rear lower frame sub-assembly with the bolt as shown in the illustration.
   

   Torque:

   8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

1. When reusing the No. 2 front door stiffener cushion:
   
   

   1. Clean the No. 2 front door stiffener cushion.
      

   2. Remove the double-sided tape from the No. 2 front door stiffener cushion.
      

   3. Wipe off any tape adhesive residue with cleaner.
      

   
   
   

   4. Apply new double-sided tape to the No. 2 front door stiffener cushion as shown in the illustration.
      

      Area	Dimension
      (A)	80.0 mm (3.150 in.)
      (B)	20.0 mm (0.787 in.)
      (C)	4.0 mm (0.157 in.)

2. Clean the front door panel sub-assembly.
   

3. Engage the 2 guides.
   

   Text in Illustration 

   *1	Double-sided Tape

4. Install the front door stiffener cushion with the 2 bolts.
   

1. Install the front door glass run.
   

NOTICE:

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

1. Using a T25 "TORX" socket wrench, install the front power window regulator motor 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.

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

2. Install the temporary bolt to the front door window regulator assembly.
   

3. Temporarily install the front door window regulator assembly.
   

   Text in Illustration 

   *1	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.
   

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

2. 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.
   

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

   NOTICE:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

4. Disconnect the power window regulator master switch assembly.
   

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.
   

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

   Torque:

   5.5 N*m{ 56 kgf*cm , 49 in.*lbf }

   HINT:

   Tighten the bolts in the order shown in the illustration.

7. Install the grommet.
   

1. Apply 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.
   

   Text in Illustration 

   *1	Reference Point

3. Attach 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.

1. Install the front door trim bracket with the 2 screws.
   

1. Install the front door trim bracket with the 2 screws.
   

1. Install the wiring harness clamp bracket with the 2 screws.
   

2. Engage the clamp.
   

1. Engage the claw to temporarily install the outer rear view mirror assembly.
   

2. Install the outer rear view mirror assembly with the 3 nuts.
   

   Torque:

   5.5 N*m{ 56 kgf*cm , 49 in.*lbf }

3. w/o Memory:
   
   

   1. Engage the clamp.
      

4. w/ Memory:
   
   

   1. Engage the clamp.
      

      HINT:

      Align the marking on the wire harness with the clamp, and then engage the clamp.

5. Connect the connector.
   

1. Attach a new outer mirror protector according to the reference points on the front door panel.
   

   Text in Illustration 

   *1	Reference Point

   NOTICE:

   Securely install the outer mirror protector preventing wrinkles and air bubbles.

1. Engage the clamp.
   

   HINT:

   Align the marking on the wire harness with the clamp, and then engage the clamp.

2. Engage the 2 claws.
   

3. Install the outer mirror install hole cover with the bolt.
   

1. Install the outer mirror control ECU assembly with the 2 screws.
   

2. Connect each connector.
   

1. Install the front No. 1 speaker assembly with the 4 bolts.
   

   NOTICE:

   Do not touch the speaker cone.

   HINT:

   Install the bolts in the order shown in the illustration.

2. Connect the connector.
   

1. Engage the clip to install a new door frame garnish.
   

1. Engage the 8 clips to install the front door trim seal.
   

1. Engage the 3 clamps and install the front door wiring sub-assembly.
   

1. Engage the 4 claws to install the seat memory switch.
   

2. Connect the connector.
   

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

1. Engage the claw and 2 guides, and install the front door inside handle sub-assembly to the front door trim board sub-assembly as shown in the illustration.
   

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

   Text in Illustration 

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

2. w/ Seat Position Memory System:
   
   

   1. Connect the connector.
      

3. Engage the 11 clips and install the front door trim board sub-assembly.
   

4. Install the 2 screws.
   

5. Remove the protective tape.
   

1. Install the door armrest cover.
   

1. Connect the connector.
   

2. Engage the 2 guides, 3 clips and 7 claws, and install the power window regulator master switch assembly with front door armrest base panel.
   

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

   Text in Illustration 

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

2. Engage the 11 clips and install the front door trim board sub-assembly.
   

3. Install the 3 screws.
   

4. Remove the protective tape.
   

1. Engage the 3 guides and install the door assist grip assembly.
   

2. Install the 2 screws.
   

1. Engage the guide and 4 claws, and install a new door assist grip cover.
   

1. Connect the connector.
   

2. Engage the 4 guides, 3 clips and 8 claws, and install the power window regulator switch assembly with front door armrest base panel.
   

1. Engage the clip and claws, and install the front door lower frame bracket garnish.
   

1. Engage the 3 claws and install the front door inside handle bezel plug.
   

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.
   

1. Engage the 6 guides.
   

2. Install the deck floor box RH with the clip.
   

1. Install the rear No. 3 floor board.
   

1. Install the rear deck floor box.
   

1. Install the rear No. 2 floor board.