DOOR / HATCH FRONT DOOR REASSEMBLY

Hide Display 1. PRECAUTION

NOTICE:: After turning the ignition 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.

Hide Display 75754A 2.INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR WINDOW FRAME MOULDING>INSTALLATION201906,999999,_59,_080736,_0392556,RM100000001HRJ3_01_0208,

Hide Display 75752A 3.INSTALL FRONT DOOR WINDOW FRAME MOULDING (FRONT PILLAR SIDE)

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR WINDOW FRAME MOULDING>INSTALLATION201906,999999,_59,_080736,_0392556,RM100000001HRJ3_01_0224,

Hide Display 67852D 4.INSTALL FRONT DOOR REAR OUTSIDE SEAL

a.

Engage the guide to install the front door rear outside seal.

Hide Display 75756D 5.INSTALL FRONT DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR WINDOW FRAME MOULDING>INSTALLATION201906,999999,_59,_080736,_0392556,RM100000001HRJ3_01_0213,

Hide Display 75792 6.INSTALL DOOR WINDOW FRAME MOULDING CLIP

a.

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

Hide Display 67811 7.INSTALL FRONT DOOR SILENCER PAD

a.

Clean the front door panel surface.

i.

Remove any remaining butyl tape from the front door panel.

ii.

Wipe off any tape adhesive residue with cleaner.

b.

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.

c.

Install the 2 front door silencer pads as shown in the illustration.

5.802,1.521 6.813,0.49 true 6.833,0.375 7.146,0.531 0.313,0.156 10 false *a 5.146,1.458 5.458,1.615 0.313,0.156 10 false a 5.813,2.135 6.125,2.292 0.313,0.156 10 false b

*a	Corner of Front Door Silencer Pad	-	-
	Installation Area of Corner of Front Door Silencer Pad		Front Door Silencer Pad Installation Area

Installation Position
Area	Measurement	Area	Measurement
a	30 mm (1.18 in.)	b	56.1 mm (2.209 in.)

Hide Display 8.INSTALL FRONT DOOR DUST PROOF SEAL

a.

Engage the 2 claws to install 2 new front door dust proof seals.

Hide Display 75720 9.INSTALL FRONT DOOR BELT MOULDING

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR BELT MOULDING>INSTALLATION202307,999999,_59,_080736,_0392553,RM100000002D3F7_01_0266,

Hide Display 67001A 10.INSTALL FRONT DOOR PANEL CUSHION

a.

Engage the 4 claws to install 2 new front door panel cushions.

Hide Display 69312 11.INSTALL FRONT DOOR LOCK OPEN ROD

a.

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	Install in this Direction (1)
	Install in this Direction (2)

Install the front door lock open rod as shown in the illustration.

Hide Display 69202A 12.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.

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Install in this Direction

Engage the guide and claw as shown in the illustration.

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.

Engage the 3 clamps.

Hide Display 69040A 13.INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

Click hereVehicle Interior>DOOR LOCK>FRONT DOOR LOCK>INSTALLATION202307,999999,_58,_080729,_0392011,RM100000002CMNW_01_0145,

Hide Display 69242E 14.INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

a.

Engage the 3 guides and claw to install the front door rear outside handle pad.

Hide Display 69241H 15.INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

a.

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

Hide Display 69217E 16.INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)

a.

Engage the 2 claws.

b.

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)

c.

Install the hole plug.

Hide Display 17.INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)

a.

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

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

b.

Install the hole plug.

Hide Display 69220 18.INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

a.

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Install in this Direction

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.

Move the lever as shown in the illustration and engage the 2 claws to secure the front door outside handle assembly.

d.

Connect the connector.

e.

Engage the 2 claws as shown in the illustration.

Hide Display 67404F 19.INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

a.

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Install in this Direction

Engage the guide as shown in the illustration.

b.

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

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

Hide Display 68216 20.INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP

a.

Install the front door fix window weatherstrip from the front door fix window glass.

b.

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Install the front door fix window weatherstrip with front door fix window glass as shown in the illustration.

Hide Display 67402F 21.INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

a.

Install the screw.

b.

Install the front door front lower frame sub-assembly with the 2 bolts.

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

Hide Display 68151D 22.INSTALL FRONT DOOR GLASS RUN

a.

Install the front door glass run.

Hide Display 23.INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY

a.

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

b.

Install the front door window regulator assembly with the 7 nuts.

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

c.

Connect the connector.

Hide Display 68102 24.INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

a.

for Driver Side:

i.

Connect the multiplex network master switch assembly.

b.

for Front Passenger Side:

i.

Connect the power window regulator switch assembly.

c.

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

d.

Turn the ignition switch (for Gasoline Model) or power switch (for HV Model) on (IG).

e.

Move the front door window regulator assembly so that the door glass bolt holes can be seen.

f.

Turn the ignition switch (for Gasoline Model) or power switch (for HV Model) off.

g.

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

h.

for Driver Side:

i.

Disconnect the multiplex network master switch assembly.

i.

for Front Passenger Side:

i.

Disconnect the power window regulator switch assembly.

j.

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	Install in this Direction (1)
	Install in this Direction (2)

Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.

NOTICE:: Do not damage the front door glass sub-assembly.

k.

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

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

l.

Install the hole plug.

Hide Display 67862 25.INSTALL FRONT DOOR WEATHERSTRIP

a.

Engage the 22 clips and install the front door weatherstrip.

Hide Display 68610 26.INSTALL FRONT DOOR CHECK ASSEMBLY

a.

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

b.

Clean the threads of the bolt (B).

c.

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

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

d.

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	Bolt (A)
	Bolt (B)

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 Display 67832 27.INSTALL FRONT DOOR SERVICE HOLE COVER

a.

Engage the 4 clips to install the front door service hole cover.

b.

Insert the 3 front door weatherstrip clips and turn them 45 degrees as shown in the illustration to install them.

Hide Display 8983AA 28.INSTALL SIDE AIRBAG PRESSURE SENSOR

Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>SIDE AIRBAG SENSOR>INSTALLATION202307,999999,_58,_080741,_0392911,RM100000002CNIP_01_0001,

Hide Display 29.INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

Click hereVehicle Exterior>MIRROR (EXT)>OUTER REAR VIEW MIRROR>INSTALLATION202307,999999,_59,_080794,_0393000,RM100000002CHT1_03_0010,

Hide Display 87964 30.INSTALL OUTER MIRROR INSTALL HOLE COVER

Click hereVehicle Exterior>MIRROR (EXT)>OUTER REAR VIEW MIRROR>INSTALLATION202307,999999,_59,_080794,_0393000,RM100000002CHT1_03_0017,

Hide Display 86160 31.INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

Click hereAudio / Visual / Telematics>AUDIO / VIDEO>FRONT DOOR SPEAKER>INSTALLATION202304,999999,_56,_080751,_0392317,RM100000002BLTQ_01_0080,

Hide Display 67836C 32.INSTALL NO. 3 FRONT DOOR SERVICE HOLE COVER

a.

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Install in this Direction

Install the No. 3 front door service hole cover as shown in the illustration.

b.

Engage the clip and connect the front door weatherstrip as shown in the illustration.

Hide Display 67838D 33.INSTALL FRONT DOOR VENT SEAL

a.

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Install in this Direction

Engage the 2 guides to install the front door vent seal to the front door inner glass weatherstrip as shown in the illustration.

b.

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Install in this Direction

Install the front door inner glass weatherstrip with front door vent seal as shown in the illustration.

Hide Display 67664C 34.INSTALL DOOR UPPER FRAME GARNISH

a.

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Install in this Direction

Engage the 2 guides as shown in the illustration.

b.

Engage the clip to install the door upper frame garnish.

Hide Display 69206B 35.INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

a.

Engage the 3 claws to install the front door inside handle sub-assembly.

Hide Display 67602 36.INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

a.

1.979,0.875 2.396,0.458 true 1.865,1.469 1.865,1.177 true 2.396,0.354 2.615,0.531 0.219,0.177 10 true *1 1.792,1.479 2.01,1.667 0.219,0.188 10 true *2

*1	Front Door Inside Lock/Unlock Knob Locking Cable
*2	Front Door Lock Open Lever Remote Control Cable
	Install in this Direction

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.

b.

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Install in this Direction

Engage the guide, 6 claws and 9 clips as shown in the illustration.

c.

Install the front door trim board sub-assembly with the 3 screws.

Hide Display 37.INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side)

a.

Connect each connector.

b.

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Install in this Direction

Engage the 5 guides, 8 claws and clip to install the multiplex network master switch assembly with front door upper armrest base panel as shown in the illustration.

Hide Display 38.INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side)

a.

Connect the connector.

b.

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Install in this Direction

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

Hide Display 74640E 39.INSTALL FRONT DOOR ASSIST GRIP ASSEMBLY

a.