Front Door Reassembly
DOOR / HATCH: FRONT DOOR: REASSEMBLY; 2013 MY FR-S [03/2012 -]
HINT
Use the same procedure for both the RH and LH sides.
1. INSTALL FRONT DOOR HOLE COVER
(a) Insert the front door hole cover with the 4 claws.
2. INSTALL DOOR SIDE AIR BAG SENSOR Installation
3. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY
4. INSTALL FRONT DOOR PANEL CUSHION
(a) Engage the 2 claws and install 2 new front door panel cushions.
5. INSTALL FRONT DOOR CHECK ASSEMBLY
(a) Apply MP grease to the sliding areas of the front door check assembly.
(b) Apply adhesive to the threads of the bolt.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Install the bolt.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
(d) Install the front door check assembly with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
6. 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 claw.
(c) Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
7. 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.
8. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
(a) Engage the 3 claws and install the front door front outside handle pad.
9. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
(a) Engage the 2 claws and install the front door rear outside handle pad.
10. 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.
(b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame sub-assembly, and then slide the front door outside handle assembly toward the front of the vehicle to install it.
11. INSTALL FRONT DOOR LOCK ASSEMBLY Installation
12. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)
(a) Engage the claw and 2 guides, and install the front door outside handle cover to the front door lock cylinder assembly.
13. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)
(a) Install the front door outside handle cover with front door lock cylinder assembly.
HINT
Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.
(b) Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly with the screw.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
14. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
(a) Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
15. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY Installation
16. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
(a) Apply MP grease to the sliding parts of the front door window regulator sub-assembly.
(b) Install the temporary bolt to the front door window regulator sub-assembly.
(c) Temporarily install the front door window regulator sub-assembly.
(d) Tighten the 3 bolts and 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(e) Tighten the temporary bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(f) Connect the connector.
17. INSTALL FRONT DOOR SASH STOPPER
(a) Install the front door sash stopper with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
18. INSTALL FRONT DOOR FIX WINDOW GLASS
(a) Insert the front door fix window glass so that it is perpendicular to the front door frame, in the order shown in the illustration.
(b) Rotate the front door fix window glass 90°.
NOTICE:
Do not damage the front door fix window glass.
(c) Install the front door fix window glass with the 3 nuts.
Nut(A) - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
Nut(B) - Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
19. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
(a) Connect the cable to the negative (-) battery terminal.
(b) Connect the power window regulator master switch assembly connector (for driver side).
(c) Connect the power window regulator switch assembly connector (for front passenger side).
(d) Move the front door glass sub-assembly until the 2 nuts can be seen through the service holes.
(e) Disconnect the cable from the negative (-) battery terminal.
(f) Disconnect the power window regulator master switch assembly connector (for driver side).
(g) Disconnect the power window regulator switch assembly connector (for front passenger side).
(h) Insert the front door glass sub-assembly into the front door frame from the position indicated in the illustration.
HINT
The front door glass sub-assembly can only be installed from the position indicated in the illustration, so install it while sliding the front door rear lower frame sub-assembly.
(i) Insert the grommet of front door glass assembly into the rail of the front door rear lower frame sub-assembly.
(j) Install the front door glass sub-assembly with the new 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
20. INSTALL DOOR GLASS INNER STABILIZER
(a) Install the door glass inner stabilizer with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
(a) Install the front door rear lower frame sub-assembly with the 3 nuts.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
22. INSTALL FRONT DOOR WEATHERSTRIP
(a) Engage the 15 clips.
(b) Engage the 2 claws.
(c) Install the front door weatherstrip with the screw.
23. INSTALL OUTER REAR VIEW MIRROR SUB-ASSEMBLY
Installation
24. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY
(a) Check the front door glass sub-assembly Adjustments.
(b) Adjust the front door glass sub-assembly Adjustments.
25. INSTALL FRONT DOOR SERVICE HOLE COVER
(a) Apply butyl tape to the front door panel.
(b) Pass the front door lock remote control cable assembly and the front door inside locking cable assembly through a new front door service hole cover.
(c) Attach the front door service hole cover according to the reference points on the front door panel.
NOTICE:
* Overlay the butyl tape in lengths of 20 cm (7.874 in.) or more.
* Do not block the drip holes in the front door panel with butyl tape.
* Securely install the front door service hole cover preventing wrinkles and air bubbles.
(d) Connect each connector.
26. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (w/ Front Speaker) Installation
27. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP
(a) Engage the 9 claws and install the front door glass inner weatherstrip to the front door trim board sub-assembly, as shown in the illustration.
(b) Install a nose piece to an air riveter or hand riveter.
(c) Insert the mandrel part of a new rivet into the nose piece.
(d) Place the riveter upright against the moulding and install the 6rivets.
HINT
If the rivet cannot be cut, pull it once and cut it.
NOTICE:
* Do not pry the rivet with the riveter as this will cause damage to the riveter and mandrel.
* Confirm that the rivets are seated properly against the front door glass inner weatherstrip.
* Do not tilt the riveter when installing the rivet to the front door glass inner weatherstrip
* Do not leave any space between the rivet head and front door glass inner weatherstrip.
28. INSTALL FRONT LOWER DOOR TRIM PAD
(a) Install the front lower door trim pad with the 5 screws.
29. INSTALL DOOR ASSIST GRIP ASSEMBLY
(a) Engage the guide and install the door assist grip assembly with the 2 screws.
30. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)
(a) Install the power window regulator master switch assembly with front door armrest base panel with the 4 screws.
31. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)
(a) Install the power window regulator switch assembly with front door armrest base panel with the 4 screws.
32. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
(a) Engage the 2 guides.
(b) Install the front door inside handle sub-assembly and spacer to the front door trim board sub-assembly with the 2 screws.
33. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY
(a) Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle.
(b) Connect each connector.
(c) Engage the 10 clips and install the front door trim board sub-assembly.
(d) Engage the clip and install the 3 screws.
(e) Engage the claw and install the cap.
34. INSTALL DOOR ARMREST COVER
(a) Engage the guide and 7 claws, and install the door armrest cover.
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)
36. INITIALIZE POWER WINDOW CONTROL SYSTEM
Programming and Relearning
37. INSPECT POWER WINDOW
Testing and Inspection