Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

1. REPAIR INSTRUCTION

2. INSTALL NO. 1 BLACK OUT TAPE

3. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

4. INSTALL FRONT DOOR REAR OUTSIDE STRIPE

5. INSTALL FRONT DOOR OUTSIDE STRIPE

6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

8. INSTALL FRONT DOOR PANEL CUSHION

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

9. INSTALL FRONT DOOR WEATHERSTRIP

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

10. 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 (A).

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the front door check assembly with the 3 bolts.

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

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

11. 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.

12. 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 door handle nut and claw.

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

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

13. INSTALL ELECTRICAL KEY WIRE HARNESS (w/ Smart Key System)

(a) Engage the 4 clamps and install the electrical key wire harness.

(b) Connect the connector.

14. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Install the front door inside locking cable assembly as shown in the illustration.

15. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

(a) Install the front door lock remote control cable assembly as shown in the illustration.

(b) Engage the 7 claws as shown in the illustration.

16. INSTALL FRONT DOOR LOCK ASSEMBLY

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

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

(b) Install a new door lock wiring harness seal to the front door lock assembly.

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

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

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

(f) Connect the connector.

17. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

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

18. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

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

19. 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) Move the lever back in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

(d) w/ smart key system:

(1) Connect the connector.

(2) Engage the 2 claws.

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

(a) Engage the claw and 2 guides, and install the front door outside handle cover to the front door lock cylinder.

21. 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.

22. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)

(a) Install the front door outside handle cover with lock cylinder assembly.

HINT
Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

(b) Using a T30 "TORX" socket wrench, install the front door lock cylinder with the screw.

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

(c) Install the hole plug.

23. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Install the front door rear lower frame sub-assembly with the bolt as shown in the illustration.

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

24. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

25. INSTALL FRONT DOOR STIFFENER CUSHION

(a) When reusing the front door stiffener cushion:

(1) Clean the front door stiffener cushion.

(2) Remove the double-sided tape from the front door stiffener cushion.

(3) Wipe off any tape adhesive residue with cleaner.

(4) Apply new double-sided tape to the front door stiffener cushion as shown in the illustration.

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

(c) Insert the front door stiffener cushion with the 2 bolts.

Text in Illustration

26. 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.

27. 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.

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

(e) Connect the connector.

28. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) Connect the cable to the negative (-) 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 (-) battery terminal and power window regulator master switch assembly.

(d) 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.

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

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

(f) Install the grommet.

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

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

29. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Apply 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.

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

Text in Illustration

NOTICE:
Securely install the front door service hole cover preventing wrinkles and air bubbles.

30. INSTALL FRONT DOOR TRIM BRACKET

(a) Install the front door trim bracket with the 2 screws.

31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

32. INSTALL DOOR FRAME GARNISH

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

33. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation

34. INSTALL OUTER MIRROR INSTALL HOLE COVER Installation

35. INSTALL OUTER MIRROR PROTECTOR Installation

36. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 7 claws and install the front door inner glass weatherstrip to the front door trim board sub-assembly as shown in the illustration.

37. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

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

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

38. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Engage the 9 clips and install the front door trim board sub-assembly.

(b) Install the 2 screws.

(c) Remove the 2 pieces of protective tape.

39. INSTALL COURTESY LIGHT ASSEMBLY Installation

40. INSTALL DOOR ARMREST COVER

(a) Install the door armrest cover.

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

(a) Connect the connector.

(b) Engage the 7 claws and 3 guides, and install the power window regulator master switch assembly with front door armrest base panel.

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

43. INSTALL ASSIST GRIP COVER

(a) Engage the 6 claws, 2 clips and 3 guides, and install the assist grip cover.

44. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

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

45. INITIALIZE POWER WINDOW CONTROL SYSTEM

Initialization

46. INSTALL REAR NO. 3 FLOOR BOARD Installation

47. INSTALL REAR DECK FLOOR BOX Installation

48. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) Installation