Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - DOOR / HATCH

FRONT DOOR - REASSEMBLY

  • HINT:
Use the same procedure for the RH side and LH side.
The procedure listed below is for the LH side.
1. INSTALL FRONT DOOR WEATHERSTRIP LH
  • HINT:
  • When installing the front door weatherstrip, heat the vehicle body and front door weatherstrip using a heat light.
  • Standard:
  • ItemTemperature
    Vehicle Body40 to 60°C (104 to 140°F)
    Front Door Weatherstrip20 to 30°C (68 to 86°F)
  • NOTICE:
  • Do not heat the vehicle body or front door weatherstrip excessively.

w/ Spot Cover:

Using a heat light, heat the vehicle body surface.

Remove the double-sided tape from the vehicle body.

Wipe off any tape adhesive residue with cleaner.

Using a heat light, heat the vehicle body and a new front door weatherstrip LH.

Remove the peeling paper from the face of the front door weatherstrip LH.

  • HINT:
  • After removing the peeling paper, keep the exposed adhesive free from foreign matter.

Attach the 21 clips to install a new front door weatherstrip LH.

  • HINT:
If clips are damaged during installation, replace them.
Press the front door weatherstrip LH firmly to install it.

w/o Spot Cover:

Attach the 21 clips to install the front door weatherstrip LH.

  • HINT:
  • If clips are damaged during installation, replace them.
2. INSTALL FRONT DOOR CHECK ASSEMBLY LH

Apply MP grease to the sliding areas of the front door check assembly LH.

Install the front door check assembly LH to the door panel with the 2 nuts.

  • Torque:
  • 8.0 N*m{ 82 kgf*cm, 71 in.*lbf}

Apply adhesive to the threads of the bolt.

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

Install the bolt.

  • Torque:
  • 27 N*m{ 275 kgf*cm, 20 ft.*lbf}
3. INSTALL FRONT DOOR CHECK COVER LH (w/ Cover)

Install the front door check cover LH.

4. INSTALL FRONT NO. 2 DOOR STIFFENER CUSHION
  • HINT:
  • When installing the front No. 2 door stiffener cushion, heat the vehicle body and front No. 2 door stiffener cushion using a heat light.
  • Standard:
  • ItemTemperature
    Vehicle Body40 to 60°C (104 to 140°F)
    Front No. 2 Door Stiffener Cushion20 to 30°C (68 to 86°F)
  • NOTICE:
  • Do not heat the vehicle body or front No. 2 door stiffener cushion excessively.

Clean the installation surface.

Using a heat light, heat the vehicle body surface.

Remove the double-sided tape from the vehicle body.

Wipe off any tape adhesive residue with cleaner.

Install a new front No. 2 door stiffener cushion.

Using a heat light, heat the vehicle body and a new front No. 2 door stiffener cushion.

Remove the peeling paper from the face of the front No. 2 door stiffener cushion.

  • HINT:
  • After removing the peeling paper, keep the exposed adhesive free from foreign matter.

Attach the 2 clamps to install the door stiffener cushion.

  • HINT:
  • Press the front No. 2 door stiffener cushion firmly to install it.

Install the 2 bolts.

5. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Entry and Start System)
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the door electrical key oscillator with the screw.

  • Torque:
  • 2.0 N*m{ 20 kgf*cm, 18 in.*lbf}
6. INSTALL FRONT DOOR LOCK OPEN ROD LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

7. INSTALL NO. 2 ELECTRICAL KEY WIRE HARNESS (w/ Entry and Start System)

Connect the connector.

Attach the 3 clamps to install the No. 2 electrical key wire harness to the frame.

8. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 2 claws to install the front door outside handle frame sub-assembly LH.

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

  • Torque:
  • 4.0 N*m{ 41 kgf*cm, 35 in.*lbf}
  • NOTICE:
  • A cover should be inserted between the screw and door panel.
9. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the front door inside locking cable assembly LH.

Attach the 3 claws.

10. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

Install the front door lock remote control cable assembly LH.

11. INSTALL FRONT DOOR LOCK ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

Insert the front door lock open rod to the front door lock assembly.

Make sure that the front door lock open rod is securely connected to the front door lock assembly.

Using a T30 "TORX" wrench, install the door lock with the 3 screws.

  • Torque:
  • 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}
12. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH

Attach the 2 claws to install the front door rear outside handle pad LH.

13. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH

Attach the 3 claws to install the front door front outside handle pad LH.

14. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Pull and hold the bellcrank lever of the frame.

Install the front door outside handle assembly LH by pushing it in the direction of the arrow in the illustration.

Using a T30 ''TORX'' socket, install the screw.

w/ Entry and Start System:

Connect the connector.

15. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 2 claws to install the front door outside handle cover LH to the front door lock cylinder.

Using a T30 ''TORX'' socket, install the front door outside cover LH (with the door lock cylinder) with the screw.

  • Torque:
  • 4.0 N*m{ 41 kgf*cm, 35 in.*lbf}

Install the hole plug.

16. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

Apply MP grease to the sliding and rotating areas of the regulator motor.

Using a T25 ''TORX'' driver, install the motor with the 3 screws.

  • Torque:
  • 5.4 N*m{ 55 kgf*cm, 48 in.*lbf}
  • HINT:
  • A new front window regulator motor uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.
17. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

  • NOTICE:
  • Do not apply grease to the spring of the front door window regulator sub-assembly LH.
Text in Illustration
*1Temporary Bolt

Loosely install the temporary bolt onto the front door window regulator sub-assembly LH.

Insert the front door window regulator sub-assembly LH into the door panel. Use the temporary bolt to hang the front door window regulator sub-assembly LH on the door panel.

  • NOTICE:
  • Be careful not to drop the front door window regulator sub-assembly LH as it may become damaged.

Temporarily install the front door window regulator sub-assembly LH with the 5 bolts.

Tighten the 6 bolts in the order shown in the illustration.

  • Torque:
  • 8.0 N*m{ 82 kgf*cm, 71 in.*lbf}
18. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

Clean the vehicle body surface.

Using a heat light, heat the vehicle body surface.

Remove the double-sided tape from the vehicle body surface.

Wipe off any tape adhesive residue with cleaner.

Install a new window frame moulding.

Using a heat light, heat a new window frame moulding and the vehicle body surface.

Remove the peeling paper from the face of the window frame moulding.

  • HINT:
  • After removing the peeling paper, keep the exposed adhesive free from foreign matter.
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the clip and double-sided tape to install the window frame moulding.

  • HINT:
  • Press the window frame moulding firmly to install it.
19. INSTALL FRONT DOOR BELT MOULDING SUB-ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the claw to install the belt moulding.

20. INSTALL LOWER DOOR FRAME GARNISH LH

Attach the clip and install a new lower door frame garnish LH.

21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH

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

22. INSTALL FRONT DOOR GLASS RUN LH

Install the front door glass run LH.

23. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Insert the front door glass sub-assembly LH into the door panel along the glass run as indicated by the arrows in the illustration.

  • NOTICE:
  • Be careful not to damage the glass.

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

  • Torque:
  • 8.0 N*m{ 82 kgf*cm, 71 in.*lbf}
24. INSTALL FRONT DOOR SERVICE HOLE COVER LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Apply butyl tape to the door.

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

  • NOTICE:
When installing the front door service hole cover LH, pull the links and connectors through the front door service hole cover LH.
There should be no wrinkles or folds after attaching the front door service hole cover LH.
After attaching the front door service hole cover LH, check the sealing quality.
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the 2 connectors.

Attach the 9 clamps.

Install the bolt as shown in the illustration.

  • Torque:
  • 8.4 N*m{ 86 kgf*cm, 74 in.*lbf}
25. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Check that the ignition switch is off.

Check that the cable is disconnected from the battery negative (-) terminal.

  • CAUTION:
  • Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

Install the side airbag sensor with the bolt.

  • Torque:
  • 9.0 N*m{ 92 kgf*cm, 80 in.*lbf}
  • NOTICE:
If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts.

Check that there is no looseness in the installation parts of the side airbag sensor.

Connect the connector.

26. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the speaker connector.

Install the speaker with the 4 screws.

  • NOTICE:
  • Do not touch the cone part of the speaker.
27. INSTALL FRONT DOOR PANEL PROTECTOR LH

Install the screw, and install the front No. 1 door stiffener cushion and front door panel protector LH.

28. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Seat Position Memory System)
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the 2 connectors.

Install the outer mirror control ECU with the 2 screws.

29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the claw and Install the mirror with the 3 nuts.

  • Torque:
  • 8.0 N*m{ 82 kgf*cm, 71 in.*lbf}

w/ Power Mirror Control System:

Attach the clamp.

Connect the connector labeled A.

30. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH

Install the front door inside handle bezel LH to the trim board with the 7 screws.

31. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH

Attach the 2 claws to install the front door inside handle sub-assembly LH.

32. INSTALL SEAT MEMORY SWITCH (w/ Seat Position Memory System)
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the seat memory switch the screw.

Connect the connector.

33. INSTALL FRONT INNER DOOR GLASS WEATHERSTRIP LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the front inner door glass weatherstrip LH.

34. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the connector.

Connect the front door lock remote control cable assembly LH and front door inside locking cable assembly LH to the front door inside handle sub-assembly LH.

Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 4 claws and 13 clips to install the front door trim board sub-assembly LH.

Install the 3 screws.

35. INSTALL DOOR ASSIST GRIP COVER LH

Attach the 8 claws to install the door assist grip cover LH to the front door trim board sub-assembly LH.

36. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the master switch with the 3 screws.

37. INSTALL FRONT UPPER ARMREST BASE PANEL LH

Connect the connector.

Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 5 claws to install the armrest base panel.

38. INSTALL FRONT DOOR INSIDE HANDLE BEZEL LH
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 4 claws to install the front door inside handle bezel LH.

39. INSTALL COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)
Front Door - Reassembly. DOOR / HATCH. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the connector.

Attach the claw of the courtesy light to the front door trim.

40. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

Attach the clip and claw, and install the front door lower frame bracket garnish LH.

41. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY LH (w/ Outside Moulding)

Attach the 3 clamps and 11 clips to install the front door outside moulding sub-assembly LH.

42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  • NOTICE:
  • When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().
43. CHECK SRS WARNING LIGHT

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DOOR / HATCH
Land Cruiser URJ200 URJ202 GRJ200 VDJ200
FRONT DOOR