Reassembly (from 07/2011)

DOOR / HATCH: FRONT DOOR (for Hatchback): REASSEMBLY

1. APPLY BODY GREASE

2. INSTALL NO. 1 BLACK OUT TAPE (for 5 Door)

HINT
Use the same procedure as for the LH side

3. INSTALL FRONT DOOR PANEL CUSHION

(a) Install the 2 cushions onto the door panel.

4. INSTALL FRONT DOOR WEATHERSTRIP (for 5 Door)

(a) Engage the 29 clips and install the front door weatherstrip.

(b) Engage the clip.

5. INSTALL FRONT DOOR WEATHERSTRIP (for 3 Door)

(a) Engage the 32 clips and install the front door weatherstrip.

(b) Engage the clip.

6. 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 bolts.

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 equivalent

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

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

7. 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.

Text in Illustration

8. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(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.

Text in Illustration

(c) Engage the grommet and 2 claws.

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

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

9. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD

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

10. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD

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

11. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

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

12. INSTALL FRONT DOOR LOCK ASSEMBLY (w/ Power Door Lock) Installation (from 07/2011)

13. INSTALL FRONT DOOR LOCK ASSEMBLY (w/o Power Door Lock) Installation (from 07/2011)

14. INSTALL FRONT DOOR OUTSIDE HANDLE COVER

(a) Engage the 2 guides.

(b) Engage the claw and install the front door outside handle cover.

(c) Temporarily install the front door outside handle cover.

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

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

(e) Install the hole plug.

15. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP

(a) Install the front door fix window glass onto the front door fix window weatherstrip.

(b) Slide the front door fix window weatherstrip, in the direction indicated by the arrow in the illustration, to install it.

16. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

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

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

17. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide.

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

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

18. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

19. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION (for 3 Door)

(a) Using a piece of cloth or similar material, rub off any double-sided tape remaining on the door panel.

(b) Using a non-residue solvent, clean the attachment surface.

(c) Remove the double-sided tape backing of the new front door No. 1 stiffener cushion.

(d) Install the front door No. 1 stiffener cushion with the 2 bolts.

Torque : 6.3 Nm (64 kgf-cm, 55 in-lbf)

20. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/ Power Window)

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

(b) Install the temporary bolt.

(c) Insert the front door window regulator into the door panel. Use the temporary bolt to hang the front door window regulator on the door panel.

Text in Illustration

(d) Tighten the 3 bolts and the temporary bolt in the order shown in the illustration.

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

(e) Install the front door window regulator with the 2 bolts.

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

(f) Connect the connector.

21. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/o Power Window)

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

(b) Install the temporary bolt.

(c) Insert the front door window regulator into the door panel. Use the temporary bolt to hang the front door window regulator on the door panel.

Text in Illustration

(d) Tighten the 2 bolts and temporary bolt in the order shown in the illustration.

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

(e) Install the front door window regulator with the 2 bolts.

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

22. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

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

(b) Connect the power window regulator master switch and move the front door glass so that the door glass bolt holes can be seen.

(c) Disconnect the cable from the negative (-) battery terminal and the power window regulator master switch.

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

NOTICE:
Do not damage the front door glass.

(e) Install the front door glass with the 2 bolts.

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

(f) Install the front door service hole cover.

23. INSTALL FRONT DOOR SERVICE HOLE COVER (for 5 Door)

(a) Apply butyl tape to the front door panel.

(b) Pass the front door lock remote control cable, front door inside locking cable and each connector through a new front door service hole cover.

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

Text in Illustration

HINT
Securely install the front door service hole cover taking care to prevent wrinkles.

24. INSTALL FRONT DOOR SERVICE HOLE COVER (for 3 Door)

(a) Apply butyl tape to the front door panel.

(b) Pass the front door lock remote control cable, front door inside locking cable and each connector through a new front door service hole cover.

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

Text in Illustration

HINT
Securely install the front door service hole cover taking care to prevent wrinkles.

25. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation (from 07/2011)

26. INSTALL DOOR SIDE AIRBAG SENSOR (w/ Curtain Shield Airbag) Installation (from 07/2011)

27. INSTALL FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

HINT
Use the same procedure as for the LH side .

28. INSTALL FRONT DOOR WINDOW FRAME REAR MOULDING (for 3 Door)

HINT
Use the same procedure as for the LH side .

29. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

HINT
Use the same procedure as for the LH side Installation (from 07/2011).

30. INSTALL FRONT DOOR WINDOW FRAME UPPER MOULDING (for Driver Side)

HINT
Use the same procedure as for the LH side .

31. INSTALL FRONT DOOR WINDOW FRAME FRONT MOULDING

HINT
Use the same procedure as for the LH side .

32. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP (for 5 Door)

(a) Engage the 7 claws and install the front door glass inner weatherstrip as shown in the illustration.

33. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP (for 3 Door)

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

34. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 4 guides and install the front door inside handle.

35. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for 5 Door)

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

Text in Illustration

(b) Engage the 7 clips and the front door trim board.

(d) Engage the claw and close the cover.

36. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY (for 3 Door)

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

Text in Illustration

(b) Engage the 8 clips and the front door trim board.

(d) Engage the claw and close the cover.

37. INSTALL FRONT ARMREST BASE UPPER PANEL (w/ Power Window)

(a) Connect the connector.

(b) Engage the 9 claws and 4 guides, and install the front armrest base upper panel.

38. INSTALL FRONT ARMREST BASE UPPER PANEL (w/o Power Window)

(a) Connect the connector.

HINT
If the armrest base upper panel is equipped with door lock switch, connect the connector.

(b) Engage the 6 claws and 3 guides, and install the front armrest base upper panel.

39. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)

(a) Install the window regulator handle plate.

Text in Illustration

(b) Open all the windows.

(c) Install the front door window regulator handle with clip at the angle shown in the illustration.

Text in Illustration

40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

41. INSPECT SRS WARNING LIGHT (w/ VSC)

Diagnosis System (from 07/2011)

42. INSPECT SRS WARNING LIGHT (w/o VSC)

Diagnosis System (from 07/2011)

43. INSPECT POWER WINDOW OPERATION

Operation Check (from 07/2011)