Reassembly

ENGINE HOOD / DOOR: FRONT DOOR: REASSEMBLY

1. INSTALL CUSHION

(a) Install the 2 cushions.

2. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

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

3. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

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

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

NOTICE:
A cover should be inserted between the nut and the door panel.

4. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD

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

5. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD

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

6. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

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

7. INSTALL FRONT DOOR LOCK Installation

8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER

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

(b) Using "Torx" socket wrench T30, install the cover with the door lock key cylinder.

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

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

(c) Install the hole plug.

9. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY Installation

10. 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) Install the front door window regulator with the 6 bolts.

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

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

(c) Connect the connector.

11. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) 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)

NOTICE:
Do not damage the glass.

(b) Install the hole plug.

12. INSTALL FRONT DOOR WINDOW FRAME REAR LOWER

(a) Install the front door window frame rear lower, and temporarily tighten the bolt.

13. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Install the front door lower frame bracket garnish with the bolt and 2 screws.

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

14. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER

(a) Install the front door frame sub-assembly front lower with the screw.

(b) Temporarily tighten the bolt.

15. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

(b) Tighten the front door window frame rear lower to the specified torque with the bolt.

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

(c) Tighten the front door frame sub-assembly front lower to the specified torque with the bolt.

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

(d) Install the hole plug.

16. INSTALL FRONT DOOR WEATHERSTRIP

(a) Install the front door weatherstrip.

17. 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 nuts.

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 the equivalent.

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

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

18. INSTALL FRONT DOOR INSIDE PANEL PLATE

(a) Install the front door inside panel plate with the 4 screws.

19. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Apply butyl tape to the door panel, then install the new front door service hole cover as shown in the illustration.

HINT
* When installing the service hole cover, pull the links out through 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.

20. INSTALL FRONT NO. 1 SPEAKER Installation

21. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

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

22. INSTALL OUTER REAR VIEW MIRROR

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

23. INSTALL FRONT NO. 2 DOOR SERVICE HOLE COVER

(a) Install the front No. 2 door service hole cover with the 4 screws.

24. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

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

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

(d) for LH side:

Close the 2 covers.

(e) for RH side:

Close the 2 covers.

25. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) Installation

26. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) Installation

27. INSTALL DOOR CONTROL SWITCH (for Front Passenger Side) Installation

28. INSTALL FRONT ARMREST BASE UPPER PANEL

(a) Connect the connector.

(b) Engage the 3 claws and clip and install the front armrest base upper panel.

29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 3.9 Nm (40 kgf-cm, 35 in-lbf)