RM38T0EC _59 Vehicle Exterior _113746 DOOR / HATCH _0510833 FRONT DOOR A

DOOR / HATCH  FRONT DOOR  REASSEMBLY  


CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)
B630952N02
0.198,4.958 1.281,5.125 1.083,0.167 3.146,1.448 3.271,1.771 3.271,1.771 3.438,1.771 false 5.438,3.417 5.438,3.75 false 2.927,5.49 3.26,5.49 false 2.885,2.354 3.219,2.354 false 0.979,3.448 1.313,3.448 false 0.906,3.906 1.24,3.906 false 0.573,4.552 0.906,4.552 false 1.073,5.375 1.24,5.375 1.24,5.375 1.406,5.208 false 2.771,0.354 3.104,0.354 false 4.24,1.25 4.354,1.115 4.354,1.115 4.521,1.115 false 1.281,5.042 1.615,5.042 false 5.531,3.771 5.896,4.125 0.365,0.354 18 false 8 3.781,1.708 3.979,1.958 0.198,0.25 10 false ● 0.854,5.24 1.219,5.594 0.365,0.354 18 false 9 3.938,1.688 4.302,2.042 0.365,0.354 18 false 7 5.01,1.01 5.375,1.365 0.365,0.354 18 false 5 3.698,2.229 4.063,2.583 0.365,0.354 18 false 6 0.344,4.427 0.708,4.781 0.365,0.354 18 false 4 4.854,1.031 5.052,1.281 0.198,0.25 10 false ● 3.531,2.26 3.729,2.51 0.198,0.25 10 false ● 3.344,5.396 3.542,5.646 0.198,0.25 10 false ● 2.896,5.5 3.135,5.74 0.24,0.24 10 false x3 1.76,4.99 2.042,5.208 0.281,0.219 10 false x2 0.958,4.51 1.24,4.729 0.281,0.219 10 false x2 1.333,3.865 1.615,4.083 0.281,0.219 10 false x2 3.51,5.365 3.875,5.719 0.365,0.354 18 false 3 0.74,3.323 1.104,3.677 0.365,0.354 18 false 2 0.698,3.792 1.063,4.146 0.365,0.354 18 false 1 3.24,0.271 3.521,0.49 0.281,0.219 10 false x7 2.604,0.26 2.802,0.51 0.198,0.25 10 false ● 1.5,5.177 1.781,5.396 0.281,0.219 10 false x2 0.281,4.969 2.729,5.125 2.448,0.156 8 false 5.0 (51, 44 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

1 NO. 2 HOLE PLUG - - - -
2 DOOR WINDOW FRAME MOULDING CLIP 75792 - - -
3 FRONT DOOR DUST PROOF SEAL 67837B - - -
4 FRONT DOOR PANEL CUSHION 67001A - - -
5 FRONT DOOR UPPER WINDOW FRAME MOULDING 75754A (Click here) - -
6 FRONT DOOR WINDOW FRAME MOULDING(CENTER PILLAR SIDE) 75756D (Click here) - -
7 FRONT DOOR BELT MOULDING ASSEMBLY 75720 - - -
8 FRONT DOOR OUTSIDE LOWER MOULDING SUB-ASSEMBLY 75074 - - -
9 HOLE PLUG - - - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

B630951N02
2.333,0.167 5,1.25 2.667,1.083 0.156,2.5 1.156,2.667 1,0.167 0.083,1 1.083,1.167 1,0.167 0.188,4.938 1.188,5.104 1,0.167 0.771,0.74 1.104,0.74 false 2.583,0.854 2.917,0.854 false 4,0.833 4.333,0.833 false 5.51,1.083 5.844,1.083 false 5,1.76 5.333,1.76 false 4.229,1.646 4.563,1.646 false 1.156,1.417 1.49,1.417 false 2.135,2.177 2.302,2.177 2.302,2.177 2.385,2.729 false 2.99,4.896 3.323,4.896 false 3.667,1.25 3.667,0.167 false 1.156,2.583 1.49,2.583 false 1.083,1.083 1.302,1.083 1.302,1.083 1.302,0.833 true 1.167,1.083 1.167,0.75 true 1.188,5.021 1.521,5.021 false 1.833,2.073 2.25,2.448 0.417,0.375 18 false 12 4.635,0.729 5.052,1.104 0.417,0.375 18 false 16 6.167,0.958 6.583,1.333 0.417,0.375 18 false 17 3.396,4.771 3.813,5.146 0.417,0.375 18 false 18 3.292,0.74 3.708,1.115 0.417,0.375 18 false 15 5.385,1.635 5.802,2.01 0.417,0.375 18 false 14 0.438,0.625 0.854,1 0.417,0.375 18 false 11 3.896,1.51 4.313,1.885 0.417,0.375 18 false 13 1.521,2.667 1.938,3.042 0.417,0.375 10 false x3 1.656,4.979 2.073,5.354 0.417,0.375 10 false x6 2.417,0.25 2.833,0.625 0.417,0.375 12 false *A 3.75,0.25 4.167,0.625 0.417,0.375 12 false *B 1.833,1.333 2.25,1.708 0.417,0.375 18 false 10 0.135,1.01 2.583,1.167 2.448,0.156 8 false 4.0 (41, 35 in.*lbf) 0.24,4.948 2.688,5.104 2.448,0.156 8 false 8.0 (82, 71 in.*lbf) 0.208,2.51 2.656,2.667 2.448,0.156 8 false 5.5 (56, 49 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

10 FRONT DOOR LOCK OPEN ROD 69312 - - -
11 FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 69202A (Click here) - -
12 FRONT DOOR LOCK WITH MOTOR ASSEMBLY 69040A (Click here) - -
13 FRONT DOOR OUTSIDE HANDLE REAR PAD 69242H - - -
14 FRONT DOOR OUTSIDE HANDLE FRONT PAD 69241H - - -
15 FRONT DOOR OUTSIDE HANDLE COVER 69217D - - -
16 FRONT DOOR LOCK CYLINDER ASSEMBLY - - - -
17 FRONT DOOR OUTSIDE HANDLE ASSEMBLY 69220 - - -
18 FRONT DOOR WINDOW REGULATOR ASSEMBLY - (Click here) - -

*A for Front Passenger Side *B for Driver Side
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
V100135

MP Grease

B630950N02
0.052,2.854 1.135,3.021 1.083,0.167 1.323,3.333 2.406,3.5 1.083,0.167 2.25,5.5 3.333,5.667 1.083,0.167 5.083,4.917 5.833,5.083 0.75,0.167 5.083,5.167 6.167,5.333 1.083,0.167 0.5,0.333 0.833,0.333 false 1.531,0.75 1.865,0.75 false 0.646,2.188 0.813,2.188 false 2.25,5 2.583,5 false 3.552,4.333 3.885,4.333 false 5.354,1.083 5.688,1.083 false 6.042,0.583 6.375,0.583 false 2.688,3.115 3.021,3.115 false 4.938,4.521 5.271,4.521 false 3.927,0.844 4.26,0.844 false 5.75,4.219 6.083,4.219 false 1.146,2.938 1.479,2.938 false 2.417,3.417 2.583,3.417 2.583,3.417 2.646,3.729 false 3.333,5.583 3.5,5.583 3.5,5.583 3.573,5.438 false 5.833,5 6,5 6,5 6.063,4.76 false 6.167,5.25 6.333,5.25 6.333,5.25 6.615,4.323 false 5.417,4.094 5.792,4.427 0.375,0.333 18 false 28 0.156,0.167 0.531,0.5 0.375,0.333 18 false 27 1.177,0.594 1.552,0.927 0.375,0.333 18 false 24 0.313,2.031 0.688,2.365 0.375,0.333 18 false 25 2.969,4.875 3.344,5.208 0.375,0.333 18 false 26 3.177,4.167 3.552,4.5 0.375,0.333 18 false 22 5,0.917 5.375,1.25 0.375,0.333 18 false 21 5.677,0.396 6.052,0.729 0.375,0.333 18 false 20 6.74,4.208 7.031,4.458 0.292,0.25 10 false x2 1.615,2.906 1.906,3.156 0.292,0.25 10 false x2 2.344,2.99 2.719,3.323 0.375,0.333 18 false 23 3.667,5.417 3.958,5.667 0.292,0.25 10 false x2 5.365,4.427 5.656,4.677 0.292,0.25 10 false *1 3.583,0.729 3.958,1.063 0.375,0.333 18 false 19 0.135,2.865 1.469,3.125 1.333,0.26 8 false 8.0 (82, 71 in.*lbf) 2.344,5.521 3.594,5.719 1.25,0.198 8 false 8.5 (87, 75 in.*lbf) 1.417,3.344 2.667,3.542 1.25,0.198 8 false 8.5 (87, 75 in.*lbf) 5.177,5.177 6.208,5.417 1.031,0.24 8 false 5.5 (56, 49 in.*lbf) 5.156,4.927 6.063,5.167 0.906,0.24 8 false 30 (306, 22) 4.906,4.917 5.063,5.115 0.156,0.198 10 false ★

Procedure Part Name Code
Z101186

Z101188

Z101187

19 NO. 2 FRONT DOOR SERVICE HOLE COVER 67831C - - -
20 FRONT DOOR FIX WINDOW WEATHERSTRIP 68216 - - -
21 FRONT DOOR FIX WINDOW GLASS 68126 - - -
22 FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 67402F - - -
23 FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 67404F - - -
24 FRONT DOOR GLASS RUN 68151D - - -
25 FRONT DOOR GLASS SUB-ASSEMBLY 68102 - - -
26 FRONT DOOR WEATHERSTRIP 67862 - - -
27 DOOR FRAME UPPER GARNISH 67664 - - -
28 FRONT DOOR CHECK ASSEMBLY 68620 (Click here) - -

*1 HOLE PLUG - -
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
V100135

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
★ Precoated part - -

B630949N02
0.25,1.333 2.583,2.5 2.333,1.167 2.75,2.25 3.75,2.417 1,0.167 2.708,2.208 3.792,2.458 1.083,0.25 0.083,3.667 1.083,3.833 1,0.167 5.885,3.417 6.885,3.583 1,0.167 6.5,0.177 6.833,0.177 false 5.958,0.833 6.292,0.833 false 2.563,0.865 2.438,0.292 2.438,0.292 2.271,0.292 false 0.927,0.448 1.125,0.448 false 3.917,1.646 4.083,1.646 false 3.208,2.646 3.542,2.646 false 1.417,1.333 1.417,2.5 false 1.104,3.083 1.438,3.083 false 4.323,3.604 4.656,3.604 false 5.542,3.76 5.542,4.094 false 4.708,5.115 5.167,5.115 false 3.594,1.188 3.5,0.646 3.5,0.646 3.333,0.646 false 0.677,4.531 0.844,4.531 0.844,4.531 0.896,4.333 false 0.833,5.5 1,5.5 1,5.5 1,5.167 false 6.542,0.458 6.875,0.458 false 0.583,2.167 0.583,2 0.583,2 0.75,1.917 false 1.833,2.177 1.833,2.01 1.833,2.01 2,1.927 false 3.615,1.948 3.25,2.083 3.25,2.083 3.25,2.25 false 1.094,3.75 1.25,3.75 1.25,3.75 1.25,4.083 false 6.385,3.417 6.385,3.25 6.385,3.25 6.719,2.417 false 6.146,0.042 6.729,0.375 0.583,0.333 18 false 43 5.604,0.708 5.969,1.042 0.365,0.333 18 false 30 3,0.521 3.365,0.854 0.365,0.333 18 false 34 1.917,0.167 2.396,0.531 0.479,0.365 18 false 36 0.552,0.323 1.063,0.677 0.51,0.354 18 false 35 3.583,1.49 3.948,1.823 0.365,0.333 18 false 29 2.854,2.51 3.344,2.896 0.49,0.385 18 false 37 1.854,2.177 2.302,2.51 0.448,0.333 18 false 39 0.552,2.156 1,2.49 0.448,0.333 18 false 40 0.292,1.375 0.573,1.729 0.281,0.354 12 false *A 1.458,1.365 1.74,1.719 0.281,0.354 12 false *B 0.76,2.958 1.333,3.354 0.573,0.396 18 false 38 0.385,4.385 0.979,4.75 0.594,0.365 18 false 42 0.531,5.406 0.99,5.729 0.458,0.323 18 false 41 1.479,4.854 1.76,5.208 0.281,0.354 10 false x2 4.083,5.375 4.365,5.729 0.281,0.354 10 false x3 3.552,3.688 3.833,4.042 0.281,0.354 10 false x3 4.708,3.479 5.073,3.813 0.365,0.333 18 false 32 5.417,4.135 5.854,4.51 0.438,0.375 18 false 31 5.479,5 5.844,5.333 0.365,0.333 18 false 33 5.74,0.313 6.625,0.688 0.885,0.375 18 false 45, 46 6.802,2.333 7.083,2.688 0.281,0.354 10 false x3 2.802,2.26 4.208,2.469 1.406,0.208 8 false 9.0 (92, 80 in.*lbf) 0.125,3.677 2.573,3.833 2.448,0.156 8 false 4.0 (41, 35 in.*lbf) 5.938,3.427 7.021,3.677 1.083,0.25 8 false 8.0 (82, 71 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

29 SIDE AIRBAG PRESSURE SENSOR 8983AA (Click here) - -
30 OUTER REAR VIEW MIRROR ASSEMBLY 87940 - - -
31 OUTER MIRROR INSTALL HOLE COVER 87964 - - -
32 FRONT NO. 1 SPEAKER ASSEMBLY 86160 (Click here) - -
33 FRONT DOOR SERVICE HOLE COVER 67832 - - -
34 FRONT DOOR FRONT BELT SEAL 68193C - - -
35 FRONT DOOR REAR BELT SEAL 68195B - - -
36 FRONT DOOR GLASS INNER WEATHERSTRIP 68172A - - -
37 FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 69206B - - -
38 FRONT DOOR TRIM BOARD SUB-ASSEMBLY 67602 - - -
39 POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL - - - -
40 MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL - - - -
41 DOOR ASSIST GRIP COVER 74646 - - -
42 FRONT DOOR INSIDE HANDLE BEZEL PLUG 69284F - - -
43 CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL - - - -
44 INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL - - - (Click here)
45 INITIALIZE POWER WINDOW CONTROL SYSTEM - - - (Click here)
46 INSPECT POWER WINDOW OPERATION - (Click here) - -
47 INSPECT POWER DOOR LOCK CONTROL SYSTEM - (Click here) - -
48 INSPECT SRS WARNING LIGHT - (Click here) - -

*A for Driver Side *B for Front Passenger Side
V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

PROCEDURE

Hide 1.INSTALL NO. 2 HOLE PLUG

Hide 75792 2.INSTALL DOOR WINDOW FRAME MOULDING CLIP

Hide 67837B 3.INSTALL FRONT DOOR DUST PROOF SEAL

Hide 67001A 4.INSTALL FRONT DOOR PANEL CUSHION

Hide 75754A 5.INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

Z101186

Click here(Click here)

Hide 75756D 6.INSTALL FRONT DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

Z101186

Click here(Click here)

Hide 75720 7.INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

Hide 75074 8.INSTALL FRONT DOOR OUTSIDE LOWER MOULDING SUB-ASSEMBLY

Click hereVehicle Exterior>DOOR / HATCH>FRONT DOOR>REASSEMBLY

Hide 9.INSTALL HOLE PLUG

Hide 69312 10.INSTALL FRONT DOOR LOCK OPEN ROD

Hide 69202A 11.INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

a.
B635682C01
2.698,0.104 2.979,0.458 0.281,0.354 18 false i 0.698,1.969 1.375,2.281 0.677,0.313 18 true ii, iii 4.125,1.979 4.677,2.333 0.552,0.354 18 false iv
V100136

Connector
V100137

MP Grease
V113147

Remove in this Direction - -


i.

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


ii.

Engage the guide to install the front door outside handle frame sub-assembly as shown in the illustration.


iii.

Using a T30 "TORX" socket wrench, tighten the screw

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


iv.

Engage the clamp to connect the wire harness.



Hide 69040A 12.INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

Z101186

Click here(Click here)

Hide 69242H 13.INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD

Hide 69241H 14.INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD

Hide 69217D 15.INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)

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

Hide 16.INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)

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

Hide 69220 17.INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

Hide 18.INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY

a.
B635681C01
0.448,0.125 0.729,0.479 0.281,0.354 18 false i 3.802,0.156 4.458,0.51 0.656,0.354 18 true ii, iii
V100135

Bolt
V100136

Connector
V100137

MP Grease - -


i.

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


ii.

Install the front door window regulator assembly with the 6 bolts.

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


iii.

Connect the connector.



Hide 67831C 19.INSTALL NO. 2 FRONT DOOR SERVICE HOLE COVER

Hide 68216 20.INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP

Hide 68126 21.INSTALL FRONT DOOR FIX WINDOW GLASS

Hide 67402F 22.INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

Torque:
8.5 N*m (87 kgf*cm, 75 in.*lbf)

Hide 67404F 23.INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

Torque:
8.5 N*m (87 kgf*cm, 75 in.*lbf)

Hide 68151D 24.INSTALL FRONT DOOR GLASS RUN

Hide 68102 25.INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

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

Hide 67862 26.INSTALL FRONT DOOR WEATHERSTRIP

Hide 67664 27.INSTALL DOOR FRAME UPPER GARNISH

Hide 68620 28.INSTALL FRONT DOOR CHECK ASSEMBLY

a.
B635687C01
0.094,0.083 1.552,1.688 1.458,1.604 2.135,0.229 2.417,0.583 0.281,0.354 18 true i 0.698,0.24 1.458,0.646 0.76,0.406 18 false ii, iii 0.646,0.573 0.927,0.927 0.281,0.354 18 false 1 0.625,1.313 0.906,1.667 0.281,0.354 18 false 2 4.073,0.104 4.354,0.458 0.281,0.354 18 true iv 5.146,0.229 5.479,0.458 0.333,0.229 10 true (A) 5.146,1.396 5.479,1.625 0.333,0.229 10 true (A) 6.458,0.885 6.792,1.115 0.333,0.229 10 true (B)
V100144

Cleaning Area
V100145

Adhesive


i.

Clean the bolt (B) hole in the vehicle body.


ii.

Clean the threads of the bolt (B).


iii.

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent



iv.

Install the front door check assembly with the 2 bolts (A) and bolt (B).

Torque:
Bolt (A) : 5.5 N*m (56 kgf*cm, 49 in.*lbf)
Bolt (B) : 30 N*m (306 kgf*cm, 22 ft.*lbf)



Hide 8983AA 29.INSTALL SIDE AIRBAG PRESSURE SENSOR

Z101186

Click here(Click here)

Hide 87964 31.INSTALL OUTER MIRROR INSTALL HOLE COVER

Hide 86160 32.INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

Z101186

Click here(Click here)

Hide 67832 33.INSTALL FRONT DOOR SERVICE HOLE COVER

Hide 68193C 34.INSTALL FRONT DOOR FRONT BELT SEAL

Hide 68195B 35.INSTALL FRONT DOOR REAR BELT SEAL

Hide 68172A 36.INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP

Hide 69206B 37.INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

Hide 67602 38.INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

a.
B633419N01
1.729,1.99 2.448,2.333 0.719,0.344 18 true iii, iv 0.26,0.104 0.552,0.406 0.292,0.302 18 true i 3.698,0.104 3.99,0.406 0.292,0.302 18 true ii 3.677,1.958 3.833,2.156 0.156,0.198 10 true A

i.

Connect the connector.


ii.

Engage the guides to connect the open lever front door lock remote control cable and front door inside lock and unlock knob locking cable.


iii.

Engage the clips to install the front door trim board sub-assembly.


iv.

Install the 3 screws.

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



Hide 39.INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side)

Hide 40.INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side)

Hide 74646 41.INSTALL DOOR ASSIST GRIP COVER

Hide 69284F 42.INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

Hide 44. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART