RM38N0EC _59 Vehicle Exterior _111831 DOOR / HATCH _0501457 FRONT DOOR A

DOOR / HATCH FRONT DOOR REASSEMBLY

CAUTION / NOTICE / HINT

HINT:: ·

Use the same procedure for the RH side and LH side.

·

The following procedure is for the LH side.

PROCEDURE

Hide Display 1. PRECAUTION

NOTICE:: After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

Hide Display 2. REPAIR INSTRUCTION

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE (for Front Door)>INSTALLATION202111,999999,_59,_111849,_0500110,RM100000001Z1DM_01_0248,

Hide Display 67856B 3.INSTALL FRONT DOOR PANEL PROTECTOR

Engage the guide to install the front door panel protector.

Hide Display 75074 4.INSTALL FRONT DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR OUTSIDE MOULDING>INSTALLATION202111,999999,_59,_111849,_0500104,RM100000001Z1CZ_01_0001,

Hide Display 5.INSTALL HOLE PLUG

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Hide Display 75922M 6.INSTALL NO. 1 BLACK OUT TAPE

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE (for Front Door)>INSTALLATION202111,999999,_59,_111849,_0500110,RM100000001Z1DM_01_0259,

Hide Display 75986B 7.INSTALL NO. 3 FRONT DOOR STRIPE

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE (for Front Door)>INSTALLATION202111,999999,_59,_111849,_0500110,RM100000001Z1DM_01_0241,

Hide Display 75926 8.INSTALL NO. 3 BLACK OUT TAPE

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>BLACK OUT TAPE (for Front Door)>INSTALLATION202111,999999,_59,_111849,_0500110,RM100000001Z1DM_01_0242,

Hide Display 75072A 9.INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR WINDOW FRAME MOULDING>INSTALLATION202111,999999,_59,_111849,_0500102,RM100000001Z1CR_01_0208,

Hide Display 75756D 10.INSTALL FRONT DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR WINDOW FRAME MOULDING>INSTALLATION202111,999999,_59,_111849,_0500102,RM100000001Z1CR_01_0213,

Hide Display 67864B 11.INSTALL FRONT DOOR NO. 2 WEATHERSTRIP

Engage the 8 clips.

Engage the clip and install the front door No. 2 weatherstrip.

Hide Display 67001A 12.INSTALL FRONT DOOR PANEL CUSHION

Engage the 2 claws to install the front door panel cushion.

Hide Display 75792 13.INSTALL DOOR WINDOW FRAME MOULDING CLIP

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

Hide Display 67862 14.INSTALL FRONT DOOR WEATHERSTRIP

Engage the 23 clips and install the front door weatherstrip.

Hide Display 68610 15.INSTALL FRONT DOOR CHECK ASSEMBLY

Clean the bolt hole in the vehicle body.

Clean the threads of the bolt.

Apply adhesive to the threads of the bolt.

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

Install the front door check assembly with the bolt and 2 nuts.

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

Hide Display 69202A 16.INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

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

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Install in this Direction

Engage the 2 guides as shown in the illustration.

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)

Hide Display 69242H 17.INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

Engage the 4 guides to install the front door rear outside handle pad.

Hide Display 69241H 18.INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

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

Hide Display 69217D 19.INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)

Engage the 2 claws.

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)

Hide Display 20.INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)

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)

Hide Display 69040A 21.INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

Click hereVehicle Interior>DOOR LOCK>FRONT DOOR LOCK>INSTALLATION202111,999999,_58,_111830,_0501507,RM100000001Z6GO_01_0145,

Hide Display 69312 22.INSTALL FRONT DOOR LOCK OPEN ROD

Click hereVehicle Interior>DOOR LOCK>FRONT DOOR LOCK>INSTALLATION202111,999999,_58,_111830,_0501507,RM100000001Z6GO_01_0206,

Hide Display 23.INSTALL HOLE PLUG

Install the hole plug.

Hide Display 69220 24.INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

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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 as shown in the illustration.

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.

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

Connect the connector.

Engage the 2 claws as shown in the illustration.

Engage the clamp.

Hide Display 68126 25.INSTALL FRONT DOOR FIX WINDOW GLASS

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Install in this Direction

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

Hide Display 67402F 26.INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

Lift up the front door weatherstrip as shown in the illustration.

Install the front door front lower frame sub-assembly with the screw and 3 bolts.

Torque:: Bolt : 8.5 N*m (87 kgf*cm, 75 in.*lbf); Screw : 3.1 N*m (32 kgf*cm, 27 in.*lbf)

Install the front door weatherstrip to the original position.

Hide Display 67404F 27.INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

Engage the guide.

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 28.INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY

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

0.49,0.167 0.646,0.375 0.156,0.208 10 true 1 1.948,1.875 2.104,2.083 0.156,0.208 10 true 2 1.615,0.115 1.771,0.323 0.156,0.208 10 true 3 0.615,0.865 0.771,1.073 0.156,0.208 10 true 4 1.948,0.083 2.104,0.292 0.156,0.208 10 true 5 2.302,1.417 2.458,1.625 0.156,0.208 10 true 6 1.406,0.979 1.563,1.188 0.156,0.208 10 true 7

Temporarily install the front door window regulator assembly with the 7 nuts.

Fully tighten the 7 nuts to install the front door window regulator assembly.

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

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

Connect the connector.

Hide Display 68151D 29.INSTALL FRONT DOOR GLASS RUN

Install the front door glass run.

Hide Display 67664C 30.INSTALL DOOR FRAME GARNISH

Engage the 3 claws to install the door frame garnish.

Hide Display 68102 31.INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

for Driver Side:

Connect the multiplex network master switch assembly.

for Front Passenger Side:

Connect the power window regulator switch assembly.

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

Turn the ignition switch to ON.

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

Turn the ignition switch off.

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

for Driver Side:

Disconnect the multiplex network master switch assembly.

for Front Passenger Side:

Disconnect the power window regulator switch assembly.

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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.

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

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

Hide Display 75720 32.INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT DOOR BELT MOULDING>INSTALLATION202111,999999,_59,_111849,_0500099,RM100000001Z1CI_01_0266,

Hide Display 33.INSTALL HOLE PLUG

Install the hole plug.

Hide Display 8983AA 34.INSTALL SIDE AIRBAG PRESSURE SENSOR

Click hereVehicle Interior>SUPPLEMENTAL RESTRAINT SYSTEMS>SIDE AIRBAG SENSOR (for Front Door)>INSTALLATION202111,202203,_58,_111838,_0502528,RM100000001ZAEC_01_0001,202203,999999,_58,_111838,_0502528,RM1000000022JFP_01_0001,

Hide Display 67832 35.INSTALL FRONT DOOR SERVICE HOLE COVER

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

Engage the 2 clamps.

Connect the connector.

Hide Display 67831D 36.INSTALL FRONT DOOR SERVICE HOLE COVER CLIP

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

Hide Display 68193C 37.INSTALL FRONT DOOR FRONT BELT SEAL

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Install in this Direction

Install the front door front belt seal as shown in the illustration.

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

Hide Display 68195B 38.INSTALL FRONT DOOR REAR BELT SEAL

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Install in this Direction

Install the front door rear belt seal to the front door inner glass weatherstrip as shown in the illustration.

Hide Display 68172A 39.INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

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Install in this Direction

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

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

Hide Display 86160 40.INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

Click hereAudio / Visual / Telematics>AUDIO / VIDEO>FRONT DOOR SPEAKER>INSTALLATION202111,999999,_56,_111822,_0500654,RM100000001Z2X0_01_0080,

Hide Display 87940 41.INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

Click hereVehicle Exterior>MIRROR (EXT)>OUTER REAR VIEW MIRROR>INSTALLATION202111,202406,_59,_111837,_0500083,RM100000001Z1AH_03_0010,202406,202409,_59,_111837,_0500083,RM100000002MQQH_03_0010,202409,999999,_59,_111837,_0500083,RM100000002OMKG_03_0010,

Hide Display 87964 42.INSTALL OUTER MIRROR INSTALL HOLE COVER

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Hide Display 69206B 43.INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

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Install in this Direction

Engage the 3 claws to install the front door inside handle sub-assembly as shown in the illustration.

Hide Display 44.INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side)

1.969,0.813 1.625,0.385 true 1.438,1.729 1.438,1.24 true 1.375,1.76 1.594,1.99 0.219,0.229 10 false *a 1.438,0.292 1.667,0.5 0.229,0.208 10 false *b

*a	Guide
*b	Clamp

Connect the connector.

Engage the clamp and guide.

Engage the 4 claws.

Install the power window regulator switch assembly with front door upper armrest base panel with the 8 screws.

Hide Display 45.INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side)

1.323,0.833 1.74,0.417 true 1.875,1.781 1.875,1.344 true 1.823,1.802 2.042,2 0.219,0.198 10 false *a 1.76,0.323 2.021,0.521 0.26,0.198 10 false *b

*a	Guide
*b	Clamp

Connect the 2 connectors.

Engage the clamp and guide.

Engage the 4 claws.

Install the multiplex network master switch assembly with front door upper armrest base panel with the 8 screws.

Hide Display 67602 46.INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

Connect the connector.

2.365,1 2.813,0.74 true 2.417,1.448 2.76,1.771 true 2.833,0.635 3.063,0.865 0.229,0.229 10 true *1 2.792,1.667 3.01,1.875 0.219,0.208 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.