Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

HINT
* Use the same procedure for the RH and LH sides.
* The procedure listed below is for the LH side.
1. INSTALL FRONT DOOR PANEL CUSHION

(a) Attach the clip to install a new door panel cushion.

2. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE LH

3. INSTALL FRONT DOOR OUTSIDE STRIPE LH

4. INSTALL NO. 1 BLACK OUT TAPE LH

5. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

6. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

7. INSTALL FRONT DOOR WEATHERSTRIP LH

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

8. INSTALL FRONT DOOR CHECK ASSEMBLY LH

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

(b) Install the door check to the door panel with the 2 nuts.

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

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the door check to the body panel with the bolt.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

9. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

(a) Clean the installation surface.

(1) Using a heat light, heat the installation surface.

HINT
When installing the front door No. 2 stiffener cushion, heat the vehicle body using a heat light.

Standard:

NOTICE:
Do not heat the door stiffener cushion and vehicle body excessively.

(2) Remove the double-sided tape from the installation surface.

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

(b) Install a new door stiffener cushion.

(1) Using a heat light, heat a new front door No. 2 stiffener cushion and the installation surface.

HINT
When installing the front door No. 2 stiffener cushion, heat the vehicle body and door stiffener cushion using a heat light.

Standard:

NOTICE:
Do not heat the door stiffener cushion and vehicle body excessively.

(2) Remove the peeling paper from the face of the door stiffener cushion.

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

(3) Attach the 2 clamps and double-sided tape to install the front door No. 2 stiffener cushion.

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

(4) Install the 2 bolts.

Torque : 6.2 Nm (63 kgf-cm, 55 in-lbf)

10. INSTALL FRONT DOOR LOCK OPEN ROD LH

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

11. INSTALL FRONT DOOR NO. 2 WIRE LH (w/ Smart Key System)

(a) Attach the 4 clamps to install the front door No. 2 wire.

12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

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

(b) Attach the door handle nut and claw.

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

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

(d) w/ Smart Key System:

(1) Attach the clamp to install the front door No. 2 wire.

(2) Connect the connector to the front door wire.

13. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH

(a) Attach the 2 claws to install the front door rear outside handle pad.

14. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH

(a) Attach the 3 claws to install the front door front outside handle pad.

15. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

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

(b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Then slide the front door outside handle assembly toward the front of the vehicle to install it.

(c) Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

(d) w/ Smart Key System:

(1) Connect the connector.

(2) Attach the 2 claws.

16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Install the front door inside locking cable assembly.

(b) Attach the 3 claws.

17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Install the front door lock remote control cable assembly.

18. INSTALL FRONT DOOR LOCK ASSEMBLY LH Installation

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

(a) Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

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

(b) Install the hole plug.

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

(a) Attach the claw and install the front door outside handle cover to the front door lock cylinder.

21. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)

(a) Install the front door outside handle cover with 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 with the screw.

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

(c) Install the hole plug.

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

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

Torque : 6.2 Nm (63 kgf-cm, 55 in-lbf)

23. INSTALL FRONT DOOR GLASS RUN LH

(a) Install the front door glass run.

24. INSTALL DOOR FRAME GARNISH LH

(a) Attach the clip to install a new door frame garnish.

25. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH Installation

26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

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

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

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

(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 Nm (82 kgf-cm, 71 in-lbf)

(e) Connect the connector.

27. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

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

(b) Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

(c) Disconnect the cable from the negative (-) battery terminal and power window regulator master switch assembly.

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

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

(d) Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows in the order shown in the illustration.

(e) Install the front door glass sub-assembly with the 2 bolts.

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

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

28. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH Installation

29. INSTALL FRONT DOOR SERVICE HOLE COVER LH

(a) Apply butyl tape to the front door panel.

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

NOTICE:
Securely install the front door service hole cover preventing wrinkles and air bubbles.

(d) Attach the 2 clamps.

(e) Install the bolt to the front door wire.

30. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH Installation

31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

32. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) Installation

33. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) Installation

34. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side) Installation

35. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH

(a) Install the front door inner glass weatherstrip.

36. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY (w/ Personal Light) Installation

37. INSTALL REAR DOOR HOLE COVER (w/o Courtesy Light)

(a) Attach the claw to install the hole cover.

38. INSTALL FRONT DOOR COURTESY LIGHT ASSEMBLY LH (w/ Courtesy Light) Installation

39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

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

(b) Connect the connector.

(c) Attach the front door trim board sub-assembly to the 4 claws of the front door inner glass as shown in the illustration.

(d) Attach the 11 clips to install the front door trim board sub-assembly.

(e) Install the 3 screws.

(f) Attach the 4 claws to install the 2 door armrest caps.

40. INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL LH

(a) Attach the 3 claws to install the inside handle bezel.

41. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

(a) Attach the 2 clips to install the front door lower frame bracket garnish.

42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

43. INITIALIZE POWER WINDOW CONTROL SYSTEM

(a) Initialize the power window control system Initialization.

44. CHECK SRS WARNING LIGHT

(a) Check the SRS warning light Diagnosis System.