Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

1. INSTALL CUSHION

(a) Install the cushion onto the door panel.

2. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Slide the front door outside handle frame and engage the claw and install it.

(b) Using "TORX" socket wrench T30, install the front door 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 3 claws and install the front door outside handle front pad.

4. INSTALL FRONT 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 Installation

7. INSTALL DOOR LOCK CYLINDER (for Driver Side)

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

8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER

(a) Using "TORX" socket wrench T30, install the front door outside handle cover.

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

(b) Install the hole plug.

9. INSTALL FRONT DOOR PANEL PROTECTOR

(a) Engage the 8 clips and install the front door panel protector.

10. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 39 clips and install the front door weatherstrip.

11. 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 : 8.5 Nm (87 kgf-cm, 75 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 : 29 Nm (296 kgf-cm, 21 ft-lbf)

12. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION

(a) Engage the 2 clips and install the front No. 1 door stiffener cushion.

13. INSTALL FRONT DOOR FRAME REAR LOWER SUB-ASSEMBLY

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

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

14. INSTALL FRONT DOOR FRAME FRONT LOWER SUB-ASSEMBLY

(a) Install the front door frame front lower sub-assembly with the 2 bolts.

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

15. 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.

16. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) Insert the door glass into the door panel 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 GLASS RUN

(a) Install the front door glass run.

18. 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.

(b) Engage the clamps and connect the connectors.

19. INSTALL FRONT DOOR NO. 1 TRIM BRACKET

(a) Install the front door No. 1 trim bracket with the 2 screws.

20. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (for Driver Side with Memory)

(a) Install the outer mirror control ECU assembly with the 2 screws.

(b) Connect the connector.

21. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

22. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation

23. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

24. INSTALL SIDE AIR BAG SENSOR ASSEMBLY Installation

25. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP

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

26. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Install the front door inside handle sub-assembly with the 3 screws.

27. INSTALL FRONT DOOR INSIDE HANDLE BEZEL

(a) Install the front door inside handle bezel with the 4 screws.

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

29. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Connect the connectors.

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

(d) Tighten the 2 screws.

(e) Install the front door armrest cover.

30. INSTALL FRONT ARMREST BASE UPPER PANEL

(a) Connect the connector.

(b) Engage the 2 clips and 5 claws and install the front armrest base upper panel.

31. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

(a) Engage the 4 claws and install the front door inside handle bezel plug

32. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Engage the 3 clips and install the front door lower frame bracket garnish.

33. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (for 14 Speakers)

(a) Connect the connector.

(b) Engage the 3 clips and install the front door lower frame bracket garnish.

34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

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

35. INSPECT SRS WARNING LIGHT

Inspect the SRS warning light Diagnosis System.