Reassembly

ENGINE HOOD / DOOR: FRONT DOOR: REASSEMBLY

1. INSTALL CUSHION

(a) Install the cushion onto the door panel.

2. 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 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)

3. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD

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

4. INSTALL REAR DOOR OUTSIDE HANDLE REAR PAD

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

5. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

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

6. INSTALL FRONT DOOR LOCK ASSEMBLY Installation

7. INSTALL FRONT DOOR OUTSIDE HANDLE COVER

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

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

(b) Install the hole plug.

8. INSTALL FRONT DOOR INSIDE PANEL REINFORCEMENT REAR EXTENSION

(a) Install the front door inside panel reinforcement rear extension with the 2 bolts.

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

9. INSTALL SEPARATION DOOR STIFFENER CUSHION

(a) Install the separation door stiffener cushion with the bolt.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

10. 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, 55 in-lbf)

11. INSTALL DOOR FRAME GARNISH

(a) Engage the clip and install a new door frame garnish.

12. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 18 clips and install the front door weatherstrip.

13. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Apply MP grease to the sliding areas of the 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)

14. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

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

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

(b) Loosely screw bolt A onto the front door window regulator.

(c) Insert the front door window regulator into the door panel. Provisionally tighten bolt A to hang the front door window regulator on the door panel.

NOTICE:
Do not drop the window regulator as it may be damaged.

(d) Install the front door window regulator with the 5 bolts, and tighten bolt A.

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

(e) Connect the connector.

15. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

16. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

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

NOTICE:
Do not damage the 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)

17. INSTALL FRONT DOOR SERVICE HOLE COVER

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

18. INSTALL REAR DOOR TRIM BRACKET

(a) Install 2 screws and install the rear door trim bracket.

19. INSTALL FRONT DOOR BELT MOULDING

20. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY 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 DOOR INSIDE HANDLE SUB-ASSEMBLY

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

24. 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 10 clips and install the front door trim board.

25. INSTALL FRONT DOOR INSIDE HANDLE BEZEL

(a) Engage the 3 claws and install the front door inside handle bezel.

26. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY Installation

27. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

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

(b) Connect the connector.

28. INSTALL FRONT DOOR ARMREST BASE UPPER PANEL

(a) Connect the connector.

(b) Engage the 6 claws and 2 clips and install the front armrest base upper panel.

(c) Install the screw.

29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)