FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Scion >> 2011 >> tC L4-2.5L (2AR-FE) >> Repair and Diagnosis >> Body and Frame >> Doors, Hood and Trunk >> Doors >> Front Door >> Service and Repair >> Reassembly

Reassembly





DOOR / HATCH: FRONT DOOR: REASSEMBLY

HINT
* Use the same procedure for the RH and LH sides.
* The procedure listed below is for the LH side.
* A bolt without a torque specification is shown in the standard bolt chart Standard Bolt - Specified Torque For Standard Bolts.

1. INSTALL NO. 1 BLACK OUT TAPE LH

2. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

3. INSTALL FRONT DOOR WEATHERSTRIP LH

(a) Attach the 17 clips to install the weatherstrip.

(b) Attach the 2 clips.

4. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Apply MP grease to the sliding areas of the door check.

(b) Install the door check to the door panel with the 2 nuts.





Torque : 5.5 Nm (56 kgf-cm, 46 in-lbf)

(c) Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the bolt.

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

5. INSTALL FRONT DOOR PANEL CUSHION

(a) Install 2 new front door panel cushions.

6. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

(a) Clean the installation surface.

(1) Using a heat light, heat the installation surface.

Standard:





NOTICE:
Do not heat the vehicle body excessively.

(2) Remove the double-sided tape from the installation surface.

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

(b) Install a new door stiffener cushion.

(1) Using a heat light, heat a new front door No. 2 stiffener cushion and the installation surface.

HINT
When installing the front door No. 2 stiffener cushion, heat the vehicle body and door stiffener cushion using a heat light.

Standard:





NOTICE:
Do not heat the door stiffener cushion and vehicle body excessively.

(2) Remove the peeling paper from the face of the door stiffener cushion.

HINT
After removing the peeling paper, keep the exposed adhesive free from foreign matter.

(3) Attach the 2 guides and double-sided tape to install the front door No. 2 stiffener cushion.

HINT
Press the front door No. 2 stiffener cushion firmly to install it.

(4) Install the 2 bolts.





Text in Illustration





7. INSTALL FRONT DOOR REAR INSIDE PANEL REINFORCEMENT EXTENSION LH

(a) Install the front door rear inside panel reinforcement extension with the 2 bolts.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

8. INSTALL FRONT DOOR LOCK OPEN ROD LH

(a) Install the front door lock open rod as indicated by the arrows in the order shown in the illustration.





9. INSTALL FRONT DOOR NO. 2 WIRE LH (w/ Smart Key System)

(a) Attach the 2 clamps to install the No. 2 electrical key wire harness.

10. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

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

(b) w/ Smart Key System:

(1) Attach the door handle nut and claw.





(2) 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)

(3) Connect the front door No. 2 wire connector to the front door wire.





(4) Attach the clamp.

(c) w/o Smart Key System:

(1) Attach the door handle nut and claw.





(2) 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)

11. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Attach the 2 claws to install the pad.

12. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Attach the 2 claws to install the pad.

13. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) w/ Smart Key System:

(1) Install the handle by pushing it in the direction of the arrow in the illustration.





(2) Attach the claw and holder of the front door outside handle frame LH.





Text in Illustration





(3) Connect the front door wire connector and attach the claw of the connector to the front door outside handle.





Text in Illustration





(4) Attach the 2 claws to fix the connector cover in place.





Text in Illustration





(b) w/o Smart Key System:

(1) Install the handle by pushing it in the direction of the arrow in the illustration.





(2) Attach the claw and holder of the front door outside handle frame LH.





Text in Illustration





14. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Install the front door lock remote control cable assembly.

15. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Install the front door inside locking cable assembly.

(b) Attach the 3 claws.

16. INSTALL FRONT DOOR LOCK ASSEMBLY LH Installation

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

(a) Attach the 3 claws to install the front door outside handle cover to the front door lock cylinder.





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





Text in Illustration





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

(c) 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)

(d) Install the hole plug.

18. INSTALL FRONT DOOR OUTSIDE HANDLE COVER RH (for Front Passenger Side)

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





Text in Illustration





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

(b) Install the hole plug.

19. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH

(a) Attach the claw to install the front door rear lower frame sub-assembly as shown in the illustration, and then install the bolt.





Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

20. INSTALL DOOR FRAME GARNISH LH

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

21. INSTALL FRONT DOOR GLASS RUN LH

(a) Attach the guide to install the front door glass run.

22. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH Installation

23. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

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

(b) Install the temporary bolt to the front door window regulator sub-assembly.





Text in Illustration





(c) Temporarily install the front door window regulator sub-assembly with the temporary bolt.

(d) Temporarily install the 5 bolts, and then tighten the temporary bolt and 5 bolts.

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

HINT
Tighten the bolts in the order shown in the illustration.

(e) Connect the connector.

24. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

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

(b) for Driver Side:

(1) Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolt installation locations can be seen.

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

(c) for Front Passenger Side:

(1) Connect the power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolt installation locations can be seen.

(2) Disconnect the cable from the negative (-) battery terminal and power window regulator 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 door glass to the window regulator with the 2 bolts.





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

25. INSTALL FRONT DOOR SERVICE HOLE COVER LH

(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 using the reference points on the front door panel.

NOTICE:
* Securely install the front door service hole cover to prevent wrinkles and air bubbles.
* There should be no wrinkles or folds after installing the service hole cover.
* After installing the service hole cover, check the seal quality.

(d) Connect the connectors.





(e) Install the door wire to the door panel with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

26. INSTALL DOOR SIDE AIRBAG SENSOR LH Installation

27. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH

(a) Install the front door inner glass weatherstrip.





28. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY Installation

29. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY Installation

30. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

31. INSTALL FRONT DOOR BELT MOULDING LH

32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH Installation

33. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH

(a) Attach the 2 claws to install the front door inside handle sub-assembly to the door trim board.

34. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

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





(b) Connect the front No. 3 speaker connector.

(c) Attach the 6 claws of the front door inner glass weatherstrip and the reference boss.





Text in Illustration





(d) Attach the 11 clips to install the trim board.

(e) Install the 3 screws.

35. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side) Installation

36. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) Installation

37. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) Installation

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

(a) Connect the connector.





(b) Attach the 9 claws and clip to install the power window regulator master switch assembly with front door armrest base panel.

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

(a) Use the same procedure described for the driver side.

40. INSTALL DOOR ASSIST GRIP COVER LH

(a) Attach the 7 claws to install the assist grip cover.





41. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH

(a) Attach the 3 claws to install the inside handle bezel plug.





42. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

(a) Attach the 2 clips to install the garnish.

43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

44. CHECK SRS WARNING LIGHT

(a) Check the SRS warning light Description and Operation.
pro multis Credits:Operation CHARM About Operation CHARM