DSD Information System
Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Door / Hatch - Service Information (1 Of 2) >> Front Door >> Reassembly [10/2022 - ] >> Procedure

Reassembly [10/2022 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch 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.

  2. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 24 clips to install the front door weatherstrip.
      GTY893571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Clean the bolt hole in the vehicle body.
    2. Clean the threads of the bolt.
    3. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the front door check assembly with the 2 nuts and bolt.
      GTY921494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Bolt

      Bolt 

      Torque: 27 N.m (275 kgf/cm, 20 ft.lbf) 

      Nut 

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

  4. INSTALL FRONT DOOR DUST PROOF SEAL 
    1. Engage the 3 claws to install 3 new front door dust proof seals.
      GTY893572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DOOR UPPER OUTSIDE MOULDING PAD 

    Refer to PROCEDURE - Step 4 [09/2020 - 11/2024] , or refer to PROCEDURE - Step 4 [11/2024 - ]

  6. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL FRONT DOOR PANEL CUSHION 
    1. Engage the claw to install a new front door panel cushion.
      GTY893573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL DOOR WINDOW FRAME MOULDING CLIP 
    1. Engage the 2 claws to install the door window frame moulding clip.
      GTY893611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER 

    Refer to PROCEDURE - Step 1

  10. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 1

  11. INSTALL FRONT DOOR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 2

  12. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 1

  13. INSTALL FRONT DOOR LOCK OPEN ROD 
    1. Install the front door lock open rod as shown in the illustration.
      GTY934989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
  14. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.
    2. Engage the guide and claw as shown in the illustration.
      GTY869463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    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) 

      GTY893619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the clamp.
      GTY893616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 5

  16. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 3 guides and claw to install the front door rear outside handle pad.
      GTY938395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the guide and 2 claws to install the front door front outside handle pad.
      GTY893622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly with the screw.
      GTY893602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the hole plug.
      GTY893603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Engage the 2 claws.
      GTY893599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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) 

    3. Install the hole plug.
      GTY893600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.
      GTY937507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. 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.
    3. Move the lever as shown in the illustration and engage the 2 claws to lock the front door outside handle assembly.
      GTY893607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector.
      GTY938392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the 2 claws as shown in the illustration.
      GTY938331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide as shown in the illustration.
      GTY944684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front door rear lower frame sub-assembly with the bolt.

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

  22. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      GTY938332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the front door window regulator assembly.
    2. Install the front door window regulator assembly with the 7 nuts.
      GTY893343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Connect the connector.
  24. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. for Driver Side:
      1. Connect the power window regulator master switch assembly.
    2. for Front Passenger Side:
      1. Connect the power window regulator switch assembly.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the ignition switch to ON.
    5. Move the front door window regulator assembly so that the door glass bolt holes can be seen.
    6. Turn the ignition switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal.
    8. for Driver Side:
      1. Disconnect the power window regulator master switch assembly.
    9. for Front Passenger Side:
      1. Disconnect the power window regulator switch assembly.
    10. Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.
      GTY936487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
    11. Install the front door glass sub-assembly with the 2 bolts.
      GTY893301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    12. Install the hole plug.
      GTY893311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL SIDE AIRBAG SENSOR ASSEMBLY 

    Refer to PROCEDURE - Step 1 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 1 [11/2023 - ]

  26. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Engage the 5 clips to install the front door service hole cover.
      GTY893317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 6 clamps.
      GTY893318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
  27. INSTALL FRONT DOOR WEATHERSTRIP CLIP 
    1. Insert the 3 front door weatherstrip clips and turn them 45 degrees as shown in the illustration to install them.
      GTY938326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  29. INSTALL FRONT DOOR PANEL PROTECTOR 
    1. Install the front door panel protector as shown in the illustration.
      GTY916931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  30. INSTALL FRONT DOOR VENT SEAL 
    1. Engage the 3 guides to install the front door vent seal to the front door inner glass weatherstrip as shown in the illustration.
      GTY907120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  31. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Install the front door inner glass weatherstrip as shown in the illustration.
      GTY896417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER 

    Refer to PROCEDURE - Step 1

  33. INSTALL OUTER MIRROR INSTALL HOLE COVER 

    Refer to PROCEDURE - Step 2

  34. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) 

    Refer to PROCEDURE - Step 1

  35. INSTALL DOOR FRAME GARNISH 
    1. Engage the 2 guides as shown in the illustration.
      GTY879837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the clip to install the door frame garnish.
  36. INSTALL SEAT MEMORY SWITCH (w/ Seat Memory Switch) 

    Refer to PROCEDURE - Step 1

  37. INSTALL DOOR ARMREST COVER SUB-ASSEMBLY 
    1. Engage the claw to install the door armrest cover sub-assembly as shown in the illustration.
      GTY860860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  38. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 3 claws to install the front door inside handle sub-assembly.
      GTY893368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. 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.
      GTY856804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Lock/Unlock Knob Locking Cable
      *2 Front Door Lock Open Lever Remote Control Cable
      Install in this Direction
    2. w/ Illumination:
      1. Connect the connector.
        GTY893372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Engage the clamp.
    3. w/ Seat Memory Switch:
      1. Connect the connector.
        GTY938339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the guide, 4 claws and 10 clips as shown in the illustration.
      GTY895647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    5. Install the front door trim board sub-assembly with the 3 screws.
      GTY893356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the claw as shown in the illustration.
      GTY893357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 2

  41. INSTALL FRONT DOOR INSIDE HANDLE BEZEL 
    1. Engage the 3 claws to install the front door inside handle bezel.
      GTY938335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. Connect each connector.
    2. Engage the 5 guides, 4 claws and 2 clips to install the multiplex network master switch assembly with front door upper armrest base panel.
      GTY893180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side) 
    1. Connect each connector.
    2. Engage the 5 guides, 6 claws and 2 clips to install the power window regulator switch assembly with front door upper armrest base panel.
      GTY893362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Engage the guide and clip to install the front door lower frame bracket garnish.
      GTY893182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    for T24A-FTS:

    Refer to PROCEDURE - Step 4 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 4 [11/2023 - ]

    for A25A-FXS:

    Refer to PROCEDURE - Step 2 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 2 [11/2023 - ]

  46. INSTALL BATTERY SERVICE HOLE COVER (for HV Model) 

    Refer to PROCEDURE - Step 3 [12/2019 - 11/2023] , or refer to PROCEDURE - Step 3 [11/2023 - ]

  47. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    Refer to INITIALIZATION [12/2019 - ]

  48. INSPECT POWER WINDOW OPERATION 

    Refer to OPERATION CHECK [12/2019 - ]

  49. INSPECT SRS WARNING LIGHT 

    Refer to OPERATION CHECK [10/2022 - 11/2023] , or refer to OPERATION CHECK [11/2023 - ]

  50. PERFORM CALIBRATION (w/ Panoramic View Monitor System) 

    Refer to CALIBRATION [10/2022 - 11/2023] , or refer to CALIBRATION [11/2023 - ]

Diesel-Data.com