Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

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

1. PRECAUTION

NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.

2. REPAIR INSTRUCTION

3. INSTALL NO. 1 BLACK OUT TAPE

4. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

5. INSTALL FRONT DOOR REAR OUTSIDE STRIPE

6. INSTALL FRONT DOOR STRIPE

7. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

8. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

9. INSTALL FRONT DOOR PANEL CUSHION

(a) Engage the 2 claws to install 2 new front door panel cushions.

10. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 17 clips and install the front door weatherstrip.

11. 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 (A).

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the front door check assembly with the 3 bolts.

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

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

12. INSTALL DOOR FRAME GARNISH

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

13. 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.

14. INSTALL FRONT DOOR WIRE (w/ Smart Key System)

(a) Engage the 2 clamps to install the front door wire.

15. 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 door handle nut and claw.

Text in Illustration

(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) Engage the clamp.

(2) Connect the connector.

16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Install the front door inside locking cable assembly as shown in the illustration.

(b) Engage the 3 claws as shown in the illustration.

17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

(a) Install the front door lock remote control cable assembly as shown in the illustration.

18. INSTALL FRONT DOOR LOCK ASSEMBLY

NOTICE:
* When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
* Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
* Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction of the front door lock assembly.

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

(b) When reusing the front door lock assembly:

(1) Install a new door lock wiring harness seal to the front door lock assembly.

Text in Illustration

HINT
Make sure that the front door lock open rod is securely connected to the front door lock assembly.

(d) Using a T30 "TORX" socket wrench, install the front door lock assembly with the 3 screws.

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

(e) Connect the connector.

19. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

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

20. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

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

21. 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.

(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) Engage the 2 claws.

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

(a) Engage the 2 guides and claw to install the front door outside handle cover to the front door lock cylinder.

23. 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 : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(b) Install the hole plug.

24. 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.

25. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide as shown in the illustration.

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

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

26. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

27. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTICE:
The regulator arm must be below the intermediate position when installing the power window regulator motor.

(a) Using a T25 "TORX" socket wrench, install the power window regulator motor assembly with the 3 screws.

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

HINT
A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

28. INSTALL FRONT DOOR POWER WINDOW REGULATOR ASSEMBLY

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

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

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

Text in Illustration

(d) Tighten the temporary bolt and 5 bolts.

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

(e) Connect the connector.

29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

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

(b) Connect the multiplex network 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 (-) auxiliary battery terminal and multiplex network master switch assembly.

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

(f) Install the grommet.

30. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Apply new 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.

(c) Attach the front door service hole cover according to the reference points on the front door panel.

Text in Illustration

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

31. INSTALL FRONT DOOR TRIM BRACKET

(a) Install the front door trim bracket with the 2 screws.

32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

33. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER Installation

34. INSTALL OUTER MIRROR INSTALL HOLE COVER Installation

35. INSTALL OUTER MIRROR PROTECTOR Installation

36. INSTALL DOOR SIDE AIRBAG SENSOR Installation

37. INSTALL COURTESY LIGHT ASSEMBLY Installation

38. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 2 claws to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

39. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 7 claws to install the front door inner glass weatherstrip to the front door trim board sub-assembly as shown in the illustration.

40. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

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

Text in Illustration

(b) Engage the 9 clips and install the front door trim board sub-assembly.

(c) Install the 2 screws.

(d) If protective tape has been applied, remove it.

41. INSTALL DOOR ARMREST COVER

(a) Install the door armrest cover.

42. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)

(a) Connect the connector.

(b) Engage the 4 guides, 11 claws and clip to install the multiplex network master switch assembly with front door armrest base panel.

43. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)

(a) Connect the connector.

(b) Engage the 4 guides, 11 claws and clip to install the power window regulator switch assembly with front door armrest base panel.

44. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

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

45. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

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

46. INSTALL DECK FLOOR BOX RH Installation

47. INSTALL REAR DECK FLOOR BOX Installation

48. INSTALL NO. 1 DECK BOARD Installation

49. INSTALL NO. 2 DECK BOARD Installation

50. INSTALL DECK BOARD ASSEMBLY Installation

51. INITIALIZE POWER WINDOW CONTROL SYSTEM

Initialization

52. INSPECT POWER WINDOW OPERATION

Operation Check

53. INSPECT SRS WARNING LIGHT

Diagnosis System