Toyota Avalon (XX50) 2019-2022 Service & Repair Manual: Reassembly

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

1. PRECAUTION

NOTICE:

After turning the engine switch (for Gasoline Model) or power switch (for HV Model) 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.

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2. REPAIR INSTRUCTION

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3. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP

(a) Install the front door No. 3 weatherstrip with the 4 clips.

(b) Install the front door panel sub-assembly with the 4 bolts. Torque: 26 N·m {265 kgf·cm, 19 ft·lbf} NOTICE: To prevent damage, when installing the front door panel sub-assembly, make sure that there are enough people available to hold it securely.

(c) Using a brush, apply anti-rust coating to the front door hinge assembly as shown in the illustration.

*A Section *1 Front Door Upper Hinge Assembly *2 Front Door Lower Hinge Assembly *a Front Door Hinge Assembly *b Anti-rust Coating

(d) Connect the connector.

(e) Engage the 4 claws to connect the grommet as shown in the illustration. NOTICE: Install the grommet with the arrow facing up.

*a Reference Point

4. INSTALL FRONT DOOR SILENCER PAD

(a) Clean the front door panel surface.

(1) Remove any remaining butyl tape from the front door panel.

(2) Wipe off any tape adhesive residue with cleaner.

(b) Remove the release paper from 2 new front door silencer pads.

HINT:

After removing the release paper, keep the exposed adhesive free from foreign matter.

(c) Install the 2 front door silencer pads as shown in the illustration.

5. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

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6. INSTALL FRONT DOOR REAR OUTSIDE SEAL

(a) Engage the guide to install the front door rear outside seal.

7. INSTALL FRONT DOOR WINDOW FRAME MOULDING (CENTER PILLAR SIDE)

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8. INSTALL NO. 1 BLACK OUT TAPE

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9. INSTALL NO. 2 BLACK OUT TAPE

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10. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

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11. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

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12. INSTALL FRONT DOOR DUST PROOF SEAL

(a) Engage the claw to install a new front door dust proof seal.

13. INSTALL DOOR WINDOW FRAME MOULDING CLIP

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

14. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP

(a) Engage the 8 clips to install the front door No. 2 weatherstrip.

15. INSTALL FRONT DOOR PANEL CUSHION

(a) Engage the 4 claws to install 2 new front door panel cushions.

16. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 23 clips and install the front door weatherstrip.

17. INSTALL DOOR FRAME GARNISH

(a) Engage the 3 claws to install the door frame garnish.

18. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Clean the bolt hole in the vehicle body.

(b) Clean the threads of the bolt.

(c) Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

	Nut
	Bolt

Torque:

Bolt :

29 N·m {296 kgf·cm, 21 ft·lbf}

Nut :

8.0 N·m {82 kgf·cm, 71 in·lbf}

19. INSTALL FRONT DOOR LOCK OPEN ROD

(a) Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

	Install in this Direction (1)
	Install in this Direction (2)

20. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

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

(b) Engage the guide and claw as shown in the illustration.

Install in this Direction

(c) 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}

21. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

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22. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 3 guides and claw to install the front door rear outside handle pad.

23. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

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

24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)

(a) Engage the 2 claws.

(b) 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}

(c) Install the hole plug.

25. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)

(a) 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}

(b) Install the hole plug.

26. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

(a) Insert the front end of the front door outside handle assembly into the front door outside handle frame sub-assembly.

Install in this Direction

(b) 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.

(c) Move the lever as shown in the illustration and engage the 2 claws to secure the front door outside handle assembly.

Engage in this Direction

(d) Engage the 3 clamps.

(e) Connect the connector.

(f) Engage the 2 claws as shown in the illustration.

Engage in this Direction

27. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide as shown in the illustration.

Install in this Direction

(b) Install the front door front lower frame sub-assembly with the 2 bolts.

28. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide as shown in the illustration.

Install in this Direction

(b) Install the front door rear lower frame sub-assembly with the 2 bolts.

29. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

30. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY

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

(b) Temporarily install the temporary bolt to the front door window regulator assembly.

(c) Temporarily install the front door window regulator assembly with the 5 bolts.

*a Temporary Bolt

(d) Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly.

HINT:

Tighten the bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(e) Connect the connector.

(f) Engage the 2 claws to install the front door No. 2 service hole cover.

31. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) for Driver Side:

(1) Connect the multiplex network master switch assembly.

(b) for Front Passenger Side:

(1) Connect the power window regulator switch assembly.

(c) for Gasoline Model:

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

(d) for HV Model:

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

(e) for Gasoline Model:

(1) Turn the engine switch on (IG).

(f) for HV Model:

(1) Turn the power switch on (IG).

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

(h) for Gasoline Model:

(1) Turn the engine switch off.

(i) for HV Model:

(1) Turn the power switch off.

(j) for Gasoline Model:

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

(k) for HV Model:

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

(l) for Driver Side:

(1) Disconnect the multiplex network master switch assembly.

(m) for Front Passenger Side:

(1) Disconnect the power window regulator switch assembly.

(n) Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.

	Install in this Direction (1)
	Install in this Direction (2)

(o) Install the front door glass sub-assembly with the 2 bolts. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

(p) Install the hole plug.

32. INSTALL FRONT DOOR VENT SEAL

(a) Install the front door vent seal as shown in the illustration.

Install in this Direction

(b) Engage the clip to connect the front door weatherstrip as shown in the illustration.

33. INSTALL FRONT DOOR PANEL PROTECTOR

(a) Install the front door panel protector as shown in the illustration.

Install in this Direction

34. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 2 guides and install the front door inner glass weatherstrip as shown in the illustration.

	Install in this Direction (1)
	Install in this Direction (2)

35. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Engage the 3 clips to install the front door service hole cover.

(b) Insert the 4 front door weatherstrip clips and turn them 45 degrees as shown in the illustration to install them.

(c) Engage the 2 clamps.

36. INSTALL FRONT DOOR TRIM BRACKET

(a) Install the front door trim bracket with the screw.

37. INSTALL SIDE AIRBAG PRESSURE SENSOR

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38. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

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39. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

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40. INSTALL OUTER MIRROR INSTALL HOLE COVER

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41. INSTALL HOLE PLUG

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42. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Engage the guide and clip to install the front door lower frame bracket garnish.

43. INSTALL HOLE PLUG

(a) Install the 2 hole plugs.

44. INSTALL PLUG PLATE (w/o Memory)

(a) Install the 2 plug plates.

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

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46. INSTALL FRONT DOOR ORNAMENT

(a) Engage the 2 guides to install the front door ornament as shown in the illustration.

Install in this Direction

47. INSTALL FRONT DOOR PULL HANDLE

(a) Engage the guide and 4 claws as shown in the illustration.

Install in this Direction

(b) Install the front door pull handle with the 2 screws.

48. INSTALL FRONT DOOR TRIM COVER

(a) Engage the 3 guides to install the front door trim cover as shown in the illustration.

Install in this Direction

(b) Engage the 2 guides as shown in the illustration.

Install in this Direction

(c) Install the front armrest assembly with front door trim cover with the 10 screws.

49. INSTALL FRONT DOOR TRIM BODY BRACKET

(a) Install the front door trim body bracket with the 3 screws.

50. INSTALL FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY

(a) Temporarily install the front door trim ornament sub-assembly as shown in the illustration.

Install in this Direction

(b) Install the front door trim ornament sub-assembly with the 8 screws.

51. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY (w/ Illumination)

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52. INSTALL FRONT DOOR INSIDE PANEL PLATE (w/ Seat Memory Switch)

(a) Engage the 2 claws to install the front door inside panel plate as shown in the illustration.

Install in this Direction

53. INSTALL SEAT MEMORY SWITCH (w/ Seat Memory Switch)

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54. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 3 claws to install the front door inside handle sub-assembly.

55. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) w/ Seat Memory Switch: (1) Connect the connector.

*A w/ Seat Memory Switch *B w/ Illumination

(b) w/ Illumination:

(1) Connect the connector.

(c) 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.

*1	Front Door Inside Lock/Unlock Knob Locking Cable
*2	Front Door Lock Open Lever Remote Control Cable
	Install in this Direction

(d) Engage the guide, 6 claws and 10 clips as shown in the illustration.

Install in this Direction

(e) Install the front door trim board sub-assembly with the 3 screws.

56. INSTALL COURTESY LIGHT ASSEMBLY

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

(a) Connect the connector.

(b) Engage the 3 claws and 3 clips to install the multiplex network master switch assembly with front door upper armrest base panel as shown in the illustration.

Install in this Direction

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

(a) Connect the connector.

(b) Engage the 3 claws to install the power window regulator switch assembly with front door upper armrest base panel as shown in the illustration.

Install in this Direction

59. INSTALL FRONT DOOR TRIM POCKET COVER

(a) Engage the 2 guides and claw to install the front door trim pocket cover.

60. INSTALL FRONT DOOR ARMREST COVER SUB-ASSEMBLY

(a) Engage the 3 claws to install the front door armrest cover sub-assembly.

61. ADJUST FRONT DOOR

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62. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for A25A-FXS:

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for 2GR-FKS:

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63. INSTALL LUGGAGE TRIM SERVICE HOLE COVER (for HV Model)

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64. INITIALIZE POWER WINDOW CONTROL SYSTEM

for Gasoline Model:

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for HV Model:

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65. INSPECT POWER WINDOW OPERATION

for Gasoline Model:

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for HV Model:

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66. INSPECT SRS WARNING LIGHT

for Gasoline Model:

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for HV Model:

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