Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

1. INSTALL CUSHION

(a) Install the cushions onto the door panel.

2. INSTALL DOOR FRAME GARNISH

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

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

(a) Engage the clamp and install the front door wire onto the front outside handle frame.

4. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System)

(a) Apply MP grease to the sliding areas of the front door outside handle frame.

(b) Slide the front door outside handle frame to install it.

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

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

5. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System)

(a) Apply MP grease to the sliding areas of the front door outside handle frame.

(e) Engage the 2 clamps.

6. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD

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

7. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD

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

8. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System)

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

(b) Pull down the door handle holder as shown by the arrow and lock the front door outside handle.

9. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System)

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

(b) Pull down the door handle holder as shown by the arrow and lock the front door outside handle.

(d) Engage the 4 claws and install the connector cover.

10. INSTALL FRONT DOOR LOCK ASSEMBLY Installation

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

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

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

(b) Install the hole plug.

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

(a) Engage the 2 claws and install the lock cylinder.

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

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

(c) Install the hole plug.

13. INSTALL FRONT DOOR STIFFENER CUSHION

(a) Install a new front door stiffener cushion with the 2 bolts and apply thorough pressure to the sections with double-sided tape.

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

Text in Illustration

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 front door window regulator spring.

(b) Loosely install 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 front door 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 REAR LOWER FRAME SUB-ASSEMBLY

(a) Install the front door rear lower frame with the 2 bolts.

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

16. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

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

NOTICE:
Do not damage the front door 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 FRONT LOWER FRAME SUB-ASSEMBLY

(a) Install the front door front lower frame with the 3 bolts.

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

(b) Install the screw.

(c) Install the service hole cover.

18. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

19. INSTALL FRONT DOOR WEATHERSTRIP

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

20. INSTALL FRONT DOOR CHECK ASSEMBLY

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

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

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

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

NOTICE:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

21. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

HINT
Use the same procedure as for the LH side .

22. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation

23. INSTALL FRONT DOOR SERVICE HOLE COVER

(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 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.

(b) Engage the clamps and connect the connector.

(c) Install the ground wire with the bolt.

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

24. INSTALL SIDE AIRBAG SENSOR Installation

25. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

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

27. INSTALL SEAT MEMORY SWITCH (for Driver Side with Memory)

HINT
Use the same procedure as for the LH side Installation.

28. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP

(a) Install the front door glass inner weatherstrip on the front door trim board and fold down the 8 claws, as shown in the illustration.

29. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

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

30. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

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

(b) Connect the connector.

(c) Engage the 10 clips and install the front door trim board.

(d) Tighten the 3 screws.

31. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

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

32. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

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

33. INSTALL FRONT DOOR ARMREST BASE PANEL ASSEMBLY

(a) Engage the 5 claws and 2 clips and install the front door armrest base panel.

34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

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