Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

HINT
* Use the same procedure for both the RH and LH sides.
* The procedure described below is for the RH side.

1. APPLY BODY GREASE

2. INSTALL CUSHION

(a) Install the 2 cushions onto the door panel.

3. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 25 clips and install the front door weatherstrip.

4. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Apply MP grease to the sliding areas of the front door outside handle frame.

(b) Slide the front door outside handle frame to install it.

(c) Using "TORX" socket wrench T30, install the front outside handle frame with the screw.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

5. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD

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

6. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD

(a) Engage the 3 claws and install the front door outside handle front pad.

7. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

(a) Pushing the front door outside handle in the direction of the arrow mark shown in the illustration, install the front door outside handle.

(b) Pull down the door handle holder as shown by the arrow and lock the front door outside handle.

8. INSTALL FRONT DOOR LOCK ASSEMBLY Installation

9. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)

(a) Engage the 2 claws and install the lock cylinder.

(b) Using "TORX" socket wrench T30, install the cover.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(c) Install the hole plug.

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

(a) Using "TORX" socket wrench T30, install the cover.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(b) Install the hole plug.

11. INSTALL FRONT DOOR FRAME REAR LOWER SUB-ASSEMBLY

(a) Install the front door frame rear lower sub-assembly with the bolt.

Torque : 6.2 Nm (63 kgf-cm, 54 in-lbf)

12. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Apply MP grease to the sliding areas of the front door check.

(b) Install the front door check onto the door panel with the 2 bolts.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(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 onto the body panel with the bolt.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

13. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

(a) Install the nut (C), engage the clamp, and install the front door window regulator.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Install the 3 nuts (B) and engage the 3 clamps.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(c) Install the 3 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(d) Engage the clamp (A).

(e) Install the regulator wire to the holder.

(f) Connect the connector.

14. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

15. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) Insert the front door glass into the door panel along the glass run as indicated by the arrows in the illustration.

NOTICE:
Do not damage the front door glass.

(b) Install the front door glass onto the front door window regulator with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

16. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Apply butyl tape to the door panel, and then install a new front door service hole cover as shown in the illustration.

HINT
* When installing the service hole cover, pull the links and connectors out through the service hole.
* There should be no wrinkles or folds after attaching the service hole cover.
* After attaching the service hole cover, check the quality of the seal.

(b) Engage the clamps.

(c) Install the ground wire with the bolt.

(d) Connect the connector.

17. INSTALL SIDE AIRBAG SENSOR Installation

18. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

HINT
Use the same procedure as for the LH side .

19. INSTALL FRONT DOOR WINDOW FRAME REAR MOULDING

HINT
Use the same procedure as for the LH side .

20. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

HINT
Use the same procedure as for the LH side Installation.

21. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

22. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP

(a) Install the front door glass inner weatherstrip.

23. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY Installation

24. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 2 claws and install the front door inside handle.

25. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Connect the front door lock remote control cable and the front door inside locking cable.

(b) Engage the 6 claws and 10 clips and install the front door trim board.

(d) Connect the connector.

26. INSTALL DOOR SPEAKER GRILLE BASE

(a) Engage the 4 claws and install the door speaker grille base.

27. INSTALL DOOR ASSIST GRIP COVER

(a) Engage the 6 claws and install the door assist grip cover.

28. INSTALL FRONT DOOR INSIDE HANDLE BEZEL

(a) Engage the 4 claws and install the front door inside handle bezel.

29. INSTALL FRONT ARMREST BASE UPPER PANEL

(a) Engage the claw and install the door armrest cap.

(b) Connect the connector.

(c) Engage the 6 claws and install the front armrest base upper panel.

(d) Install the screw.

(e) Engage the claw and close the door armrest cap.

30. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Engage the 2 guides and the clip and install the front door lower frame bracket garnish.

31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 5.4 Nm (55 kgf-cm, 49 in-lbf)

32. INSPECT SRS WARNING LIGHT

Diagnosis System

33. INSPECT POWER WINDOW OPERATION

Operation Check