RM36D0EC _59 Vehicle Exterior _083093 DOOR / HATCH _0403687 FRONT DOOR A

DOOR / HATCH  FRONT DOOR  REASSEMBLY  


CAUTION / NOTICE / HINT

HINT:
·

Use the same procedure for the RH and LH sides.

·

The procedure below is for the LH side.



PROCEDURE

Hide 67001A 1.INSTALL FRONT DOOR PANEL CUSHION

a.
B522056

Attach the claw and install the front door panel cushion.

HINT:

Use the same procedure described for the other side.



Hide 2.INSTALL HOLE PLUG

a.
B522057

Install the hole plug.

HINT:

Use the same procedure described for the other side.



Hide 3.INSTALL SCREW GROMMET

a.
B522055

Attach the claw and install the screw grommet.

HINT:

Use the same procedure described for the other side.



Hide 67864B 5.INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH

a.
B598198C01
0.031,0.042 0.271,0.25 0.24,0.208 12 true *A 0.094,2.417 0.333,2.625 0.24,0.208 12 true *B
*A for Type A
*B for Type B


Attach the clip and install the front door No. 2 weatherstrip LH.


Hide 75792 7.INSTALL DOOR WINDOW FRAME MOULDING CLIP

a.
B524160

Attach the claw to install a new door window frame moulding clip.


Hide 67862 10.INSTALL FRONT DOOR WEATHERSTRIP LH

a.
B522062

Attach the clip and install the front door weatherstrip LH.


b.
B536491C01
1.01,0.906 1.323,1.063 0.313,0.156 10 false *a 1.01,1.969 1.323,2.125 0.313,0.156 10 false *b
*a Correct
*b Incorrect


Check that the front door weatherstrip LH is securely installed to the rail of the front door outside moulding sub-assembly LH as shown in the illustration.

NOTICE:

If the front door weatherstrip LH is not securely installed, water may leak into the vehicle.



Hide 68610 11.INSTALL FRONT DOOR CHECK ASSEMBLY

a.

When reusing a bolt (B):

i.

Clean the threads of the bolt with non-residue solvent.


ii.

Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.




b.
B522051C01
0,0 0,0 false
V100135

Bolt (A)
V100136

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 69720D 13.INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

Hide 69318C 15.INSTALL DOOR LOCK WIRING HARNESS SEAL

Hide 69202A 17.INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

a.

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


b.
B522044

w/ Entry and Start System:

i.

Attach the wire harness clamp.



c.
B522068C01
0.167,0.083 0.438,0.333 0.271,0.25 10 true *a 0.146,2.417 0.417,2.667 0.271,0.25 10 true *b
*a Inside
*b Outside


Attach the guide as shown in the illustration.


d.

Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly LH with the "TORX" screw.

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


Hide 69312 18.INSTALL FRONT DOOR LOCK OPEN ROD LH

a.
B522069C01
0,0 0,0 false
V113147

Install in this Direction


Install the front door lock open rod LH on the front door lock with motor assembly LH as shown in the illustration.

HINT:

Check that the front door lock open rod LH is securely attached to the front door lock with motor assembly LH.



b.
B522070C01
1.219,0.531 1.927,0.344 true 1.979,0.229 2.219,0.417 0.24,0.188 10 false *1
*1 Snap
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Install the front door lock open rod LH to the front door outside handle frame sub-assembly LH and attach the snap of the front door outside handle as shown in the illustration.


Hide 69242F 19.INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

a.
B522041

Attach the guide and install the front door rear outside handle pad.


Hide 69241H 20.INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

a.
B522040

Attach the claw and guide to install the front door front outside handle pad.


Hide 21.INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY LH (for Driver Side)

a.

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


b.
B522035

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

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


c.
B522034

Install the hole plug.


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

a.
B522071C01
0,0 0,0 false
V113147

Install in this Direction


Attach the claw of the front door outside handle cover in the direction indicated by the arrow.


b.
B522038

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

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


c.
B522037

Install the hole plug.


Hide 69220 23.INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

a.
B522072C01
0,0 0,0 false
V113147

Install in this Direction


Install the front door outside handle assembly LH in the direction of the arrow shown in the illustration.


b.
B522073C01
1.521,0.75 1.104,0.563 true 0.865,0.417 1.083,0.635 0.219,0.219 10 true *1
*1 Holder
V113147

Install in this Direction


Attach the holder as shown in the illustration.


c.
B522074

w/ Entry and Start System:

i.

Attach the claw to connect the connector and connector cover.


ii.
B522075C01
0,0 0,0 false
V113147

Install in this Direction


Attach the claw and close the connector cover as shown in the illustration.



Hide 68126 24.INSTALL FRONT DOOR FIX WINDOW GLASS LH

a.
B522076C01
0,0 0,0 false
V113147

Install in this Direction


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


Hide 67402F 25.INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH

a.
B522077C01
0,0 0,0 false
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Temporarily install the front door front lower frame sub-assembly LH in the direction indicated by the arrows, in the order shown in the illustration.


b.

Install the 3 bolts.

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


c.
B522027C01
0,0 0,0 false
V113147

Lift up in this Direction


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


d.

Install the screw.


Hide 67404F 26.INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH

a.
B522026

Attach the guide.


b.

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

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


Hide 69802 28.INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

a.

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


b.
B522079C01
0,0 0,0 false
V113147

Install in this Direction


Insert the front door window regulator sub-assembly LH from the service hole as shown in the illustration.


c.
B522024C03
1.354,1.854 1.49,2.031 0.135,0.177 10 true 1 0.969,0.042 1.104,0.219 0.135,0.177 10 true 1 1.042,0.719 1.177,0.896 0.135,0.177 10 true 2 1.833,0.146 1.969,0.323 0.135,0.177 10 true 2 2.49,0.344 2.625,0.521 0.135,0.177 10 true 3 1.781,0.969 1.917,1.146 0.135,0.177 10 true 5 2.396,1.24 2.531,1.417 0.135,0.177 10 true 4
V100135

Nut
V100136

Connector


Install the front door window regulator sub-assembly LH with the 7 nuts in the order shown in the illustration.

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

NOTICE:

Do not damage the front door panel with the front door window regulator sub-assembly LH.



d.

Connect the connector.


Hide 68151E 29.INSTALL FRONT DOOR GLASS RUN LH

a.
B522080N01
0.417,1.427 0.583,1.604 0.167,0.177 10 true A 0.865,1.333 1.031,1.51 0.167,0.177 10 false A 1.76,0.667 1.969,0.875 0.208,0.208 10 false B 1.823,0.208 2.031,0.396 0.208,0.188 10 false B 2.51,1.635 2.667,1.823 0.156,0.188 10 true C 2.969,1.604 3.125,1.792 0.156,0.188 10 true C 0.542,2.292 0.906,2.49 0.365,0.198 10 false A-A 1.594,1.156 2.125,1.396 0.531,0.24 10 false B-B 2.552,2.292 3.125,2.583 0.573,0.292 10 false C-C

Install the front door glass run LH to the groove in front door front lower frame sub-assembly LH and front door rear lower frame sub-assembly LH.


Hide 67664C 30.INSTALL DOOR FRAME GARNISH LH

a.
B522081C01
0,0 0,0 false
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Attach the guide and install the door frame garnish LH in the direction indicated by the arrows, in the order shown in the illustration.


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

a.

for Driver Side:

i.

Connect the multiplex network master switch assembly connector.



b.

for Front Passenger Side:

i.

Connect the power window regulator switch assembly connector.




d.

Turn the ignition switch to ON.


e.

Move the front door window regulator sub-assembly LH until the installation bolts can be seen.


f.
B522082C01
0,0 0,0 false
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Temporarily install the front door glass sub-assembly LH to the front door window regulator assembly LH in the order shown in the illustration.

NOTICE:

Be careful not to damage the front door glass sub-assembly LH.



g.
B522020

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

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


h.

Move the front door glass sub-assembly LH until the open position.


i.

Turn the ignition switch off.


j.

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

CAUTION:
B394718

·

Wait at least 60 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

·

If the airbag deploys for any reason, it may cause a serious accident.









k.

for Driver Side:

i.

Disconnect the multiplex network master switch assembly connector.



l.

for Front Passenger Side:

i.

Disconnect the power window regulator switch assembly connector.



m.

Remove the protective tape.


n.
B522018

Install the hole plug.


Hide 67832 34.INSTALL FRONT DOOR SERVICE HOLE COVER LH

a.
B522083C01
0,0 0,0 false
V113147

Install in this Direction


Pass the front door lock remote control cable assembly and front door inside locking cable assembly through the front door service hole cover LH.


b.
B522084C01
1.177,0.177 1.448,0.156 true 0.979,0.073 1.156,0.24 0.177,0.167 10 true *a 2.438,1.938 2.563,2.115 0.125,0.177 10 true 1 1.333,0.271 1.458,0.448 0.125,0.177 10 true 2 1.76,1.833 1.885,2.01 0.125,0.177 10 true 3 2.854,1.219 2.979,1.396 0.125,0.177 10 true 3
*a Clip A


Align with the position of clip A as shown in the illustration.


c.

Attach the clip and install the front door service hole cover LH in the order shown in the illustration.


d.
B526925C01
1.302,2.375 1.542,2.375 false 1.573,2.281 1.885,2.479 0.313,0.198 10 false *a
*a Bead Mark
V113147

Turn in this Direction
V100135

Service Hole Cover Clip


Install the service hole cover clip knob at an angle of 45°.


e.

Turn the service hole cover clip 45° clockwise and align the positions of the bead mark and knob.

HINT:

Use the same procedure for the other service hole cover clips.



f.
B522014

Attach the clamp.


g.

Connect the connector.


Hide 68193C 38.INSTALL FRONT DOOR FRONT BELT SEAL LH

a.
B522086C01
0,0 0,0 false
V113147

Install in this Direction


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


b.
B522087C01
0,0 0,0 false
V113147

Install in this Direction


Attach the guide and partially install the front door weatherstrip LH with the clip.


Hide 68195B 39.INSTALL FRONT DOOR REAR BELT SEAL LH

a.
B522088C01
0,0 0,0 false
V113147

Install in this Direction


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


Hide 68172A 40.INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH

a.
B522139C01
0,0 0,0 false
V113147

Install in this Direction


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


b.
B522140C01
0,0 0,0 false
V113147

Install in this Direction


Attach the guide and partially install the front door weatherstrip LH with the clip.


Hide 69206B 41.INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH

a.
B522141C01
0,0 0,0 false
V113147

Install in this Direction


Temporarily install the front door inside handle sub-assembly LH in the direction indicated by the arrow as shown in the illustration.


b.
B522007

Attach the claw and clamp to install the front door inside handle sub-assembly LH.


Hide 67602 42.INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

a.
B522142C01
2.281,0.854 2.698,0.792 true 2.24,1.354 2.521,1.74 true 2.76,0.656 2.958,0.833 0.198,0.177 10 true *1 2.5,1.833 2.688,2 0.188,0.167 10 true *2
*1 Front Door Inside Locking Cable Assembly
*2 Front Door Lock Remote Control Cable Assembly
V113147

Install in this Direction


Attach the clamp and connect the front door lock remote control cable assembly and front door inside locking cable assembly to the front door inside handle sub-assembly as shown in the illustration.


b.
B522143C01
2.896,1.333 3.021,1.531 0.125,0.198 10 true 1 0.354,1.688 0.479,1.885 0.125,0.198 10 true 2 2.583,1.771 2.708,1.969 0.125,0.198 10 true 3 2.583,1.313 2.708,1.51 0.125,0.198 10 true 4 2.26,1.344 2.385,1.542 0.125,0.198 10 true 5 1.948,1.365 2.073,1.563 0.125,0.198 10 true 6 1.604,1.375 1.729,1.573 0.125,0.198 10 true 7 1.24,1.375 1.365,1.573 0.125,0.198 10 true 8 0.792,1.396 0.917,1.594 0.125,0.198 10 true 9
V113147

Install in this Direction


Attach the claw and clip to install the front door trim board sub-assembly LH in the direction indicated by the arrow shown in the illustration.

HINT:

Attach the claw and clip as shown in the illustration.



c.
B522144C01
0,0 0,0 false
V113147

Install in this Direction


Attach the clip and install the 3 screws as shown in the illustration.


d.

Remove the protective tape.


Hide 84040 45.INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side)

Hide 46.INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)

a.

Connect the 2 connectors.


b.
B522147C01
0,0 0,0 false
V113147

Install in this Direction


Attach the guide in the direction indicated by the arrow shown in the illustration.


c.
B522148C01
0,0 0,0 false
V113147

Install in this Direction


Attach the guide and claw to install the multiplex network master switch assembly with front door armrest base panel.


d.

Remove the protective tape.


Hide 47.INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)

a.

Connect the connector.


b.
B522145C01
0,0 0,0 false
V113147

Install in this Direction


Attach the guide in the direction indicated by the arrow shown in the illustration.


c.
B522146C01
0,0 0,0 false
V113147

Install in this Direction


Attach the guide and claw to install the power window regulator switch assembly with front door armrest base panel.


d.

Remove the protective tape.


Hide 74640C 48.INSTALL DOOR ASSIST GRIP ASSEMBLY LH

a.
B522149C01
0,0 0,0 false
V113147

Install in this Direction


Attach the guide in the direction indicated by the arrow shown in the illustration.


b.
B522150C01
0.667,1.208 0.802,1.396 0.135,0.188 10 true 1 1.021,1.146 1.156,1.333 0.135,0.188 10 true 2 1.344,1.094 1.479,1.281 0.135,0.188 10 true 3 1.677,1.01 1.813,1.198 0.135,0.188 10 true 4 1.927,0.948 2.063,1.135 0.135,0.188 10 true 5 2.125,0.781 2.26,0.969 0.135,0.188 10 true 4 2.219,0.5 2.354,0.688 0.135,0.188 10 true 3 2.427,0.24 2.563,0.427 0.135,0.188 10 true 2 2.854,0.615 2.99,0.802 0.135,0.188 10 true 3 2.771,0.927 2.906,1.115 0.135,0.188 10 true 4 1.813,1.708 1.948,1.896 0.135,0.188 10 true 4 1.458,1.781 1.594,1.969 0.135,0.188 10 true 3 1.094,1.885 1.229,2.073 0.135,0.188 10 true 2 0.75,1.969 0.885,2.156 0.135,0.188 10 true 1
V113147

Install in this Direction


Attach the claw in the order shown in the illustration.


c.

Attach the clip and install the door assist grip assembly LH.


d.

Remove the protective tape.


Hide 69278B 49.INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH

a.
B521991

Attach the claw and install the door inside handle bezel LH.


Hide 51. 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