| Last Modified: 01-30-2024 | 6.11:8.1.0 | Doc ID: RM100000001RIO7 |
| Model Year Start: 2021 | Model: RAV4 | Prod Date Range: [08/2020 - ] |
| Title: DOOR / HATCH: FRONT DOOR: REASSEMBLY; 2021 - 2024 MY RAV4 RAV4 HV [08/2020 - ] | ||
REASSEMBLY
CAUTION / NOTICE / HINT
HINT:
- Use the same procedure for the RH and LH sides.
- The procedure below is for the LH side.
PROCEDURE
1. INSTALL FRONT DOOR PANEL CUSHION
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(a) Attach the claw and install the front door panel cushion. HINT: Use the same procedure described for the other side. |
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2. INSTALL HOLE PLUG
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(a) Install the hole plug. HINT: Use the same procedure described for the other side. |
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3. INSTALL SCREW GROMMET
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(a) Attach the claw and install the screw grommet. HINT: Use the same procedure described for the other side. |
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4. INSTALL FRONT DOOR LOWER OUTSIDE MOULDING SUB-ASSEMBLY LH
Click here
![2019 - 2024 MY RAV4 RAV4 HV [11/2018 - ]; EXTERIOR PANELS / TRIM: FRONT DOOR OUTSIDE MOULDING: INSTALLATION+](/t3Portal/stylegraphics/info.gif)
5. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH
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(a) Attach the clip and install the front door No. 2 weatherstrip LH. |
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6. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING LH
Click here
7. INSTALL DOOR WINDOW FRAME MOULDING CLIP
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(a) Attach the claw to install a new door window frame moulding clip. |
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8. INSTALL FRONT DOOR PANEL PROTECTOR LH
Click here
9. INSTALL DOOR WINDOW FRAME MOULDING LH (CENTER PILLAR SIDE)
Click here
10. INSTALL FRONT DOOR WEATHERSTRIP LH
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(a) Attach the clip and install the front door weatherstrip LH. |
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(b) 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. |
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11. INSTALL FRONT DOOR CHECK ASSEMBLY LH
(a) When reusing a bolt (B):
(1) Clean the threads of the bolt with non-residue solvent.
(2) Apply adhesive to the threads of the bolt.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
(b) Install the front door check assembly LH with the 2 bolts (A) and bolt (B).
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Bolt (A) |
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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}
12. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY
Click here
13. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
Click here
14. INSTALL FRONT DOOR LOCK COVER SUB-ASSEMBLY LH
Click here
15. INSTALL DOOR LOCK WIRING HARNESS SEAL
(a) When reusing front door lock with motor assembly LH:
Click here
16. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY LH
Click here
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.
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(b) w/ Smart Key System: (1) Attach the wire harness clamp. |
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(c) Attach the guide as shown in the illustration. |
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(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}
18. INSTALL FRONT DOOR LOCK OPEN ROD LH
(a) Install the front door lock open rod LH on the front door lock with motor assembly LH as shown in the illustration.
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Install in this Direction |
HINT:
Check that the front door lock open rod LH is securely attached to the front door lock with motor assembly LH.
(b) 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.
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*1 |
Snap |
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Install in this Direction (1) |
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Install in this Direction (2) |
19. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
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(a) Attach the guide and install the front door rear outside handle pad. |
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20. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
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(a) Attach the claw and guide to install the front door front outside handle pad. |
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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.
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(b) 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} |
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(c) Install the hole plug. |
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22. INSTALL FRONT DOOR OUTSIDE HANDLE COVER RH (for Front Passenger Side)
(a) Attach the claw of the front door outside handle cover RH in the direction indicated by the arrow.
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Install in this Direction |
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(b) 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} |
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(c) Install the hole plug. |
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23. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH
(a) Install the front door outside handle assembly LH in the direction of the arrow shown in the illustration.
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Install in this Direction |
(b) Attach the holder as shown in the illustration.
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*1 |
Holder |
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Install in this Direction |
(c) w/ Smart Key System:
(1) Attach the claw to connect the connector and connector cover.
(2) Attach the claw and close the connector cover as shown in the illustration.
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Install in this Direction |
24. INSTALL FRONT DOOR FIX WINDOW GLASS LH
(a) Install the front door fix window glass LH as shown in the illustration.
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Install in this Direction |
25. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH
(a) 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.
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Install in this Direction (1) |
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Install in this Direction (2) |
(b) Install the 3 bolts.
Torque:
8.5 N·m {87 kgf·cm, 75 in·lbf}
(c) Lift up the front door weatherstrip LH and install the screw as shown in the illustration.
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Lift up in this Direction |
(d) Install the screw.
26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH
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(a) Attach the guide. |
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(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}
27. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
Click here
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) Insert the front door window regulator sub-assembly LH from the service hole as shown in the illustration.
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Install in this Direction |
(c) 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.
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Nut |
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Connector |
(d) Connect the connector.
29. INSTALL FRONT DOOR GLASS RUN LH
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(a) 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. |
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30. INSTALL DOOR FRAME GARNISH LH
(a) Attach the guide and install the door frame garnish LH in the direction indicated by the arrows, in the order shown in the illustration.
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Install in this Direction (1) |
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Install in this Direction (2) |
31. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
(a) for Driver Side:
(1) Connect the multiplex network master switch assembly connector.
(b) for Front Passenger Side:
(1) Connect the power window regulator switch assembly connector.
(c) Connect the cable to the negative (-) auxiliary battery terminal.
(1) for A25A-FXS:
Click here
(2) for A25A-FKS:
Click here
(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) Temporarily install the front door glass sub-assembly LH to the front door window regulator assembly LH in the order shown in the illustration.
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Install in this Direction (1) |
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Install in this Direction (2) |
NOTICE:
Be careful not to damage the front door glass sub-assembly LH.
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(g) Install the front door glass sub-assembly LH with the 2 bolts. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf} |
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(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.
(1) for A25A-FXS:
Click here
(2) for A25A-FKS:
Click here
CAUTION:
- After disconnecting the cable from the negative (-) auxiliary battery terminal, wait for at least 90 seconds to start the operation.
- If the airbag deploys for any reason, it may cause a serious accident.
(k) for Driver Side:
(1) Disconnect the multiplex network master switch assembly connector.
(l) for Front Passenger Side:
(1) Disconnect the power window regulator switch assembly connector.
(m) Remove the protective tape.
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(n) Install the hole plug. |
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32. INSTALL FRONT DOOR BELT MOULDING LH
Click here
33. INSTALL SIDE AIRBAG PRESSURE SENSOR LH
Click here
34. INSTALL FRONT DOOR SERVICE HOLE COVER LH
(a) Pass the front door lock remote control cable assembly and front door inside locking cable assembly through the front door service hole cover LH.
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Install in this Direction |
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(b) Align with the position of clip A as shown in the illustration. |
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(c) Attach the clip and install the front door service hole cover LH in the order shown in the illustration.
(d) Install the service hole cover clip knob at an angle of 45°.
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*a |
Bead Mark |
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Turn in this Direction |
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Service Hole Cover Clip |
(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.
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(f) Attach the clamp. |
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(g) Connect the connector.
35. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
Click here
36. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
Click here
37. INSTALL OUTER MIRROR INSTALL HOLE COVER LH
Click here
38. INSTALL FRONT DOOR FRONT BELT SEAL LH
(a) Install the front door front belt seal LH as shown in the illustration.
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Install in this Direction |
(b) Attach the guide and partially install the front door weatherstrip LH with the clip.
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Install in this Direction |
39. INSTALL FRONT DOOR REAR BELT SEAL LH
(a) Install the front door rear belt seal LH to the front door inner glass weatherstrip LH as shown in the illustration.
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Install in this Direction |
40. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH
(a) Install the front door inner glass weatherstrip LH with front door rear belt seal LH as shown in the illustration.
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Install in this Direction |
(b) Attach the guide and partially install the front door weatherstrip LH with the clip.
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Install in this Direction |
41. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH
(a) Temporarily install the front door inside handle sub-assembly LH in the direction indicated by the arrow as shown in the illustration.
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Install in this Direction |
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(b) Attach the claw and clamp to install the front door inside handle sub-assembly LH. |
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42. INSTALL SEAT MEMORY SWITCH (w/ Seat Memory Switch)
Click here
43. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
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(a) w/ Seat Memory Switch: (1) Connect the connector. |
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(b) 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.
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*1 |
Front Door Inside Locking Cable Assembly |
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*2 |
Front Door Lock Remote Control Cable Assembly |
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Install in this Direction |
(c) 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.
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Install in this Direction |
HINT:
Attach the claws and clips as shown in the illustration.
(d) Attach the clip and install the 3 screws as shown in the illustration.
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Install in this Direction |
(e) Remove the protective tape.
44. INSTALL DOOR CONTROL SWITCH ASSEMBLY (w/ Door Control Switch)
Click here
45. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)
Click here
46. INSTALL OUTER MIRROR SWITCH ASSEMBLY (for Driver Side)
Click here
47. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side)
Click here
48. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)
(a) Connect the 2 connectors.
(b) Attach the guide in the direction indicated by the arrow shown in the illustration.
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Install in this Direction |
(c) Attach the guide and claw to install the multiplex network master switch assembly with front door armrest base panel.
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Install in this Direction |
(d) Remove the protective tape.
49. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)
(a) w/ Door Control Switch:
(1) Connect the 2 connectors.
(b) w/o Door Control Switch:
(1) Connect the connector.
(c) Attach the guide in the direction indicated by the arrow shown in the illustration.
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Install in this Direction |
(d) Attach the guide and claw to install the power window regulator switch assembly with front door armrest base panel.
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Install in this Direction |
(e) Remove the protective tape.
50. INSTALL FRONT DOOR ASSIST GRIP COVER LH
(a) Attach the guide in the direction indicated by the arrow shown in the illustration.
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Install in this Direction |
(b) Attach the claw in the order shown in the illustration.
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Install in this Direction |
(c) Attach the clip and install the front door assist grip cover LH.
(d) Remove the protective tape.
51. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH
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(a) Attach the claw and install the door inside handle bezel LH. |
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52. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL
(a) for A25A-FXS:
Click here
(b) for A25A-FKS:
Click here
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click here
53. INSTALL BATTERY HOLE COVER (for HV Model)
Click here
54. INSTALL REAR NO. 2 FLOOR BOARD (for HV Model)
Click here
55. INSTALL DECK BOARD ASSEMBLY (for HV Model)
Click here
56. INSPECT SRS WARNING LIGHT
Click here
57. PERFORM DIAGNOSTIC SYSTEM CHECK
Click here
58. INITIALIZE POWER WINDOW CONTROL SYSTEM
Click here
59. CHECK POWER WINDOW CONTROL SYSTEM
Click here
60. CHECK POWER DOOR LOCK CONTROL SYSTEM
Click here
61. INSPECT OUTER REAR VIEW MIRROR OPERATION
Click here
62. INSPECT CHECK FRONT POWER SEAT CONTROL SYSTEM (for Power Seat)
(a) for HV Model:
Click here
(b) for Gasoline Model:
(1) w/ Memory:
Click here
(2) w/o Memory:
Click here
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