Reassembly

ENGINE HOOD / DOOR: FRONT DOOR: REASSEMBLY

HINT
* Use the same procedures for the RH side and LH side.
* The procedures listed below are for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart Standard Bolt - Specified Torque For Standard Bolts.
1. INSTALL CUSHION

(a) Install the 2 cushions.

2. INSTALL FRONT DOOR WEATHERSTRIP LH

(a) Attach the 17 clips to install the weatherstrip.

3. INSTALL FRONT DOOR GLASS RUN LH

4. INSTALL FRONT DOOR CHECK ASSEMBLY LH

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

(b) Install the door check to the door panel with the 2 bolts labeled A.

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

(c) Apply adhesive to the bolt labeled B.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

5. INSTALL FRONT DOOR OUTSIDE HANDLE PAD LH

(a) Attach the 2 claws to install the pad.

6. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Attach the 2 claws to install the pad.

7. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System)

(a) Install the door electrical key oscillator with the screw.

8. INSTALL NO. 2 ELECTRICAL KEY WIRE HARNESS (w/ Smart Key System)

(a) Attach the claw to install the wire harness to the frame.

(b) Connect the connector.

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

(a) Install the front door lock open rod.

(b) Attach the claw and clip to install the frame.

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

(d) w/ Smart Key System:

(1) Attach the 4 clamps to install the wire harness to the door panel.

(2) Connect the connector.

10. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) w/o Smart Key System:

(b) Install the handle by pushing and sliding it in the direction indicated by the arrow in the illustration.

(c) w/ Smart Key System:

(1) Install the handle by pushing and sliding it in the direction indicated by the arrow in the illustration.

(2) Connect the connector.

11. INSTALL FRONT DOOR LOCK ASSEMBLY LH

(a) Apply MP grease to the sliding and rotating areas of the front door lock.

(b) Install the 2 cables as shown in the illustration.

(d) Install a new door lock wire harness packing.

NOTICE:
* When reinstalling the door lock, always use new packing.
* Do not allow grease or dirt to contaminate the gap between the door panel and packing.
* Old or damaged packing cannot effectively protect against water which can damage the door lock.
(e) Install the control rod to the door lock, and then set the door lock to the door panel.

NOTICE:
Make sure that the rod is securely engaged with the lock.

(f) Apply adhesive to the threads of the 3 screws.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(g) Using a T30 "TORX" socket, install the door lock with the 3 screws.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(h) Connect the connector.

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

(a) Install the door lock cylinder to the cover.

(b) Tighten the screw using a T30 "TORX" socket to install the cover (with cylinder).

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

HINT
Make sure that the door lock cylinder rod is inserted into the door lock.

(c) Install the hole plug.

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

(a) Tighten the screw using a T30 "TORX" socket to install the cover.

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

(b) Install the hole plug.

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

(a) Install the frame with the bolt.

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

15. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

(a) Using a T25 "TORX" driver, install the motor with the 3 screws.

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

HINT
For a new window regulator motor, the screw holes will be tapped and the installation position of the regulator motor will be set when the self-tapping screws are installed.

16. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

(a) Apply MP grease to the sliding and rotating areas of the window regulator.

NOTICE:
Do not apply grease to the spring of the window regulator.

(b) Install the regulator with the 6 bolts.

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

NOTICE:
Be careful not to drop the window regulator as it may become damaged.

(c) Connect the connector.

17. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

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

NOTICE:
Be careful not to damage the glass.

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

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

18. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH

19. INSTALL FRONT DOOR SERVICE HOLE COVER LH

(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 out the links and connectors through the service hole cover.
* There should be no wrinkles or folds after attaching the service hole cover.
* After attaching the service hole cover, check the seal quality.
(b) Connect each connector.

20. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH

(a) Connect the 2 cables to the inside handle to install the inside handle.

21. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY Installation

22. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

23. INSTALL OUTER REAR VIEW MIRROR SUB-ASSEMBLY LH Installation

24. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Attach the 4 claws to install the speaker door grille.

(b) Attach the 7 claws to install the weatherstrip inner.

(c) Attach the 2 claws to install the inside handle to the trim board.

(d) Attach the 10 clips to install the trim board.

(e) Install the 3 screws.

(f) Attach the 3 claws to install the door inside handle bezel plug.

(g) Attach the 12 claws to install the door assist grip.

25. INSTALL FRONT UPPER ARMREST BASE PANEL LH

(a) for Driver Side:

(b) Install the power window regulator master switch to the panel with the 3 screws.

(c) for Passenger Side:

(d) Attach the 2 claws to install the power window regulator switch to the panel.

(e) for Passenger Side:

(f) Attach the 2 claws to install the door control switch to the panel.

(g) Connect the switch connector(s).

(h) Attach the clip and 5 claws to install the panel (with the switch(es)).

26. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH

(a) Attach the clip and 3 claws to install the garnish.

27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL