Reassembly

ENGINE HOOD / DOOR: FRONT DOOR: REASSEMBLY

1. INSTALL CUSHIONS

(a) Install the cushions onto the door panel.

2. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Apply MP grease to the sliding areas of the front door outside handle frame sub-assembly.

(b) Slide the outside handle frame sub-assembly to install it.

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

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

3. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD

(a) Engage the 2 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 ASSEMBLY Installation

7. INSTALL LOCK CYLINDER (for Driver Side)

(a) Engage the 2 claws and install lock cylinder.

8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER

(a) Using "TORX" socket wrench T30, install the cover.

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

(b) Install the hole plug.

9. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION

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

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

10. INSTALL FRONT DOOR FRAME FRONT LOWER SUB-ASSEMBLY

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

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

11. INSTALL FRONT DOOR FRAME REAR LOWER SUB-ASSEMBLY

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

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

12. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 32 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) Install the front door check assembly 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)

14. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

(a) Apply MP grease to the sliding and rotating areas of the front door window regulator sub-assembly.

NOTICE:
Do not apply grease to the front door window regulator spring.

(b) Loosely screw bolt A onto the front door window regulator sub-assembly.

(c) Insert the front door window regulator sub-assembly into the door panel. Provisionally tighten bolt A to hang the front door window regulator sub-assembly on the door panel.

NOTICE:
Do not drop the front door window regulator sub-assembly as it may be damaged.

(d) Install the front door window regulator sub-assembly with the 5 bolts, and tighten bolt A.

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

(e) Connect the connector.

15. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

16. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) Insert the front door glass sub-assembly into the door panel along the glass run as indicated by the arrows in the illustration.

NOTICE:
Do not damage the front door glass sub-assembly.

(b) Install the front door glass sub-assembly onto the front door window regulator with the 2 bolts.

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

17. 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.
18. INSTALL FRONT DOOR TRIM BRACKET

(a) Install 2 screws and install the rear door trim bracket.

19. INSTALL FRONT DOOR BELT MOULDING

20. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation

21. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

22. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP

(a) Install the front door glass inner weatherstrip on the front door trim board assembly and fold down the 7 claws, as shown in the illustration.

23. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 2 claws and install the front door inside handle sub-assembly.

24. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

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

(b) Engage the 7 clips and install the front door trim board sub-assembly.

25. INSTALL FRONT DOOR INSIDE HANDLE BEZEL

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

26. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY Installation

27. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Engage the 2 guides and clip and install the front door lower frame bracket garnish.

(b) Connect the connector.

28. INSTALL FRONT DOOR ARMREST BASE UPPER PANEL

(a) Connect the connector.

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

(c) Install the front door armrest cover.

29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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