Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

1. PRECAUTION

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

2. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

3. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

4. REPAIR INSTRUCTION

5. INSTALL FRONT DOOR REAR OUTSIDE STRIPE

6. INSTALL FRONT DOOR OUTSIDE STRIPE

7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

8. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

9. INSTALL DOOR DUST PROOF SEAL

(a) Install door dust proof seal.

10. INSTALL FRONT DOOR PANEL CUSHION

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

11. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP

(a) Engage the 8 clips to install the front door No. 2 weatherstrip.

12. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 20 clips and install a new front door weatherstrip.

Text in Illustration

13. 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 front door check assembly with the bolt and 2 nuts.

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

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

14. 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.

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.

(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)

16. INSTALL FRONT DOOR WIRE

(a) Engage the 5 clamps and install the electrical key wire harness.

(b) Connect the connector.

17. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

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

(b) Engage the 3 claws.

18. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

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

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

Text in Illustration

(d) Make sure that the front door lock open rod is securely connected to the front door lock assembly.

(e) 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)

(f) Connect the connector.

20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

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

21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

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

22. 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) Connect the connector.

(e) Engage the 2 claws.

23. 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 as shown in the illustration.

24. 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.

25. 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.

26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide.

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

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

27. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION

(a) When reusing the No. 2 front door stiffener cushion:

(1) Clean the No. 2 front door stiffener cushion.

(2) Remove the double-sided tape from the No. 2 front door stiffener cushion.

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

(4) Apply new double-sided tape to the No. 2 front door stiffener cushion as shown in the illustration.

(b) Clean the front door panel sub-assembly.

(c) Engage the 2 guides.

Text in Illustration

(d) Install the front door stiffener cushion with the 2 bolts.

28. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

29. INSTALL FRONT 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 front 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.

30. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY

(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.

Text in Illustration

(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.

31. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(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.

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) Disconnect the power window regulator master switch assembly.

(e) 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.

(f) 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.

(g) Install the grommet.

32. 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 front door inside locking cable assembly through a new front door service hole cover.

Text in Illustration

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

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

33. INSTALL DOOR SIDE AIRBAG SENSOR Installation

34. INSTALL FRONT DOOR TRIM BRACKET (for Driver Side)

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

35. INSTALL FRONT DOOR TRIM BRACKET (for Front Passenger Side)

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

36. INSTALL WIRING HARNESS CLAMP BRACKET (w/o Memory)

(a) Install the wiring harness clamp bracket with the 2 screws.

(b) Engage the clamp.

37. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation

38. INSTALL OUTER MIRROR PROTECTOR Installation

39. INSTALL OUTER MIRROR INSTALL HOLE COVER Installation

40. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) Installation

41. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

42. INSTALL DOOR FRAME GARNISH

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

43. INSTALL FRONT DOOR TRIM SEAL

(a) Engage the 8 clips to install the front door trim seal.

44. INSTALL SEAT MEMORY SWITCH (w/ Seat Position Memory System) Installation

45. INSTALL FRONT DOOR WIRING SUB-ASSEMBLY (w/ Seat Position Memory System)

(a) Engage the 3 clamps and install the front door wiring sub-assembly.

46. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 8 claws to install the front door inner glass weatherstrip as shown in the illustration.

47. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the claw and 2 guides, and install the front door inside handle sub-assembly to the front door trim board sub-assembly as shown in the illustration.

48. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for Driver Side)

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

Text in Illustration

(b) w/ Seat Position Memory System:

(1) Connect the connector.

(c) Engage the 11 clips and install the front door trim board sub-assembly.

(d) Install the 3 screws.

(e) Remove the protective tape.

49. INSTALL DOOR ARMREST COVER (for Driver Side)

(a) Install the door armrest cover.

50. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)

(a) Connect the connector.

(b) Engage the 2 guides, 3 clips and 7 claws, and install the power window regulator master switch assembly with front door armrest base panel.

51. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for Front Passenger Side)

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

Text in Illustration

(b) Engage the 11 clips and install the front door trim board sub-assembly.

(c) Install the 3 screws.

(d) Remove the protective tape.

52. INSTALL DOOR ASSIST GRIP ASSEMBLY (for Front Passenger Side)

(a) Engage the 3 guides and install the door assist grip assembly.

(b) Install the 2 screws.

53. INSTALL DOOR ASSIST GRIP COVER (for Front Passenger Side)

(a) Engage the guide and 4 claws, and install the door assist grip cover.

54. 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, 3 clips and 8 claws, and install the power window regulator master switch assembly with front door armrest base panel.

55. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

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

56. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

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

57. 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.

58. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE Installation

59. INSTALL DECK FLOOR BOX RH Installation

60. INSTALL REAR NO. 3 FLOOR BOARD Installation

61. INSTALL REAR DECK FLOOR BOX Installation

62. INSTALL REAR NO. 2 FLOOR BOARD Installation

63. INITIALIZE POWER WINDOW CONTROL SYSTEM

Initialization

64. INSPECT SRS WARNING LIGHT

Diagnosis System