Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

HINT
* Use the same procedure for both the RH and LH sides.
* The procedure described below is for the LH side.

1. PRECAUTION

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

2. REPAIR INSTRUCTION

3. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

4. INSTALL FRONT DOOR STRIPE

5. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

8. INSTALL DOOR DUST PROOF SEAL

(a) Install door dust proof seal.

9. INSTALL FRONT DOOR PANEL CUSHION

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

10. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP

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

11. INSTALL DOOR FRAME GARNISH

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

12. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 19 clips and install the front door weatherstrip.

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 3 bolts.

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

Bolt (B) - Torque : 5.5 Nm (56 kgf-cm, 49 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 WIRE

(a) Engage the 3 clamps to install the front door wire.

16. 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 claw.

Text in Illustration

(c) Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw and door handle nut.

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

(d) Engage the 3 clamps.

(e) 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 WITH MOTOR ASSEMBLY

NOTICE:
* When reusing the removed front door lock with motor 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 with motor assembly.

(a) Apply MP grease to the sliding parts of the front door lock with motor assembly.

(b) When reusing the front door lock with motor assembly:

(1) Install a new door lock wiring harness seal to the front door lock with motor assembly.

Text in Illustration

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

(e) Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

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

21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the 3 claws to 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) Connect the connector.

(d) Engage the 2 claws.

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

(a) Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly 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) Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw.

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

(b) Install the hole plug.

26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide as shown in the illustration.

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

27. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide as shown in the illustration.

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

28. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

29. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION

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

(b) Engage the 2 guides.

Text in Illustration

(c) Install a new No. 2 front door stiffener cushion with the 2 bolts.

30. 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.

31. 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)

32. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

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

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary 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 : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(g) Install the grommet.

33. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Apply new 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.

(d) Engage the 5 clamps.

(e) Install the bolt.

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

(f) Connect each connector.

34. INSTALL DOOR SIDE AIRBAG SENSOR Installation

35. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation

36. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

37. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Install the front door inner glass weatherstrip.

38. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 2 claws and guide, and install the front door inside handle sub-assembly to the front door trim board sub-assembly.

39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

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

Text in Illustration

(b) Engage the front door trim board sub-assembly with the 4 claws and reference boss as shown in the illustration.

Text in Illustration

(d) Install the 3 screws.

(e) If protective tape has been applied, remove it.

40. INSTALL COURTESY LIGHT ASSEMBLY Installation

41. INSTALL FRONT ARMREST ASSEMBLY

(a) Engage the 2 guides, 3 clips and 7 claws, and install the front armrest assembly.

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

(a) Connect each connector.

(b) Engage the 4 guides, 2 clips and 5 claws, and install the power window regulator master switch assembly with front door armrest base panel.

43. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)

(a) Connect each connector.

(b) Engage the 4 guides, 2 clips and 5 claws, and install the power window regulator switch assembly with front door armrest base panel.

44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

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

45. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

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

46. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

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

47. INSTALL LUGGAGE TRIM SERVICE HOLE COVER Installation

48. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side)

Initialization

49. INSPECT POWER WINDOW OPERATION

Operation Check

50. INSPECT SRS WARNING LIGHT

for Separate Type Yaw Rate Sensor: Separate Type Yaw Rate Sensor

for Built-in Type Yaw Rate Sensor: Built-in Type Yaw Rate Sensor