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Front Door: Reassembly

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL FRONT DOOR UPPER WINDOW FRAME MOLDING  (See INSTALLATION )
  2. INSTALL FRONT DOOR REAR WINDOW FRAME MOLDING  (See INSTALLATION )
  3. INSTALL FRONT DOOR BELT MOLDING ASSEMBLY  (See INSTALLATION )
  4. INSTALL FRONT DOOR FRAME COVER  (See INSTALLATION )
  5. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 21 clips.
    2. Install the front door weatherstrip with the double-sided tape
      Fig 1: Identifying Front Door Weatherstrip And Clips
      G05321217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Install the front door check assembly with the bolt and the 2 nuts.

      Torque: 

      Bolt 

      27 N*m (275 kgf*cm, 20 ft.*lbf) 

      Nut 

      8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 2: Identifying Front Door Check Assembly
      G05321216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DOOR CHECK COVER 
    1. Install the front door check cover.
    Fig 3: Identifying Front Door Check Cover
    G05321215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY  (See INSTALLATION )
  9. INSTALL OUTER MIRROR PROTECTOR  (See INSTALLATION )
  10. INSTALL DOOR ELECTRICAL KEY OSCILLATOR  (See INSTALLATION )
  11. INSTALL FRONT DOOR LOCK OPEN ROD 
    1. Install the front door lock open rod as shown in the illustration
    Fig 4: Identifying Front Door Lock Open Rod
    G05756026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly
    2. Install the front door outside handle frame sub-assembly with the claws.
      3. Fig 5: Identifying Front Door Outside Handle Frame Sub-Assembly With Claws
      G05756027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

    4. Engage the 2 clamps
    5. Connect the connector.
  13. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the front door inside locking cable assembly.
      Fig 6: Identifying Front Door Inside Locking Cable Assembly
      G05252793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 3 claws.
      Fig 7: Identifying Front Door Inside Locking Cable Assembly Claws
      G05320722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the front door lock remote control cable assembly
    Fig 8: Identifying Front Door Lock Remote Control Cable Assembly
    G05321210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT DOOR LOCK ASSEMBLY 
    NOTE:
    • When reusing the removed front door lock assembly, replace the door lock wire 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 and/or using damaged door lock wiring harness seal may cause water intrusion. This may result in a malfunction in the front door lock assembly.
    1. Apply MP grease to the sliding parts of the front door lock assembly
    2. Install a new door lock wiring harness seal to the front door lock assembly
    3. Insert the front door lock open rod to the front door lock assembly, and set it to the front door outside handle frame.
    4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.
    5. Using a "TORX" socket wrench (T30), install the front door lock assembly with the 3 screws

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 9: Identifying Front Door Lock Assembly Screws
      G05320720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the front door rear outside handle pad
      Fig 10: Identifying Front Door Rear Outside Handle Pad And Claws
      G05321208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the front door front outside handle pad.
      Fig 11: Identifying Front Door Front Outside Handle Pad And Claws
      G05254235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Insert the front end of the front door outside handle assembly into the front door outside handle frame.
    2. 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 to the front of the vehicle to install it.
      Fig 12: Inserting Front End Of Front Door Outside Handle Assembly
      G05252823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a "TORX" socket wrench (T30), install the front door outside handle assembly with the screw

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 13: Locating Front Door Outside Handle Assembly And Screws
      G05756005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector
  19. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Install the front door lock cylinder assembly.

      HINT:

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

      Fig 14: Installing Front Door Lock Cylinder Assembly
      G05756036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a "TORX" socket wrench (T30), install the front door lock cylinder assembly with the screw

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

      Fig 15: Identifying Front Door Lock Cylinder Assembly (For Driver Side)
      G05252819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the hole plug.
  20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side) 
    1. Engage the 2 claws of the front door outside handle cover
      Fig 16: Identifying Front Door Outside Handle Cover And Claws
      G05254270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Using a "TORX" socket wrench (T30), install the front door outside handle cover with the screw

      Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

    2. Install the hole plug.
      Fig 17: Identifying Front Door Outside Handle Cover (For Front Passenger Side)
      G05756004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Install the front door rear lower frame sub-assembly with the bolt
      Fig 18: Identifying Front Door Rear Lower Frame Sub-Assembly With Bolt
      G05321239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Install the front door front lower frame sub-assembly with the 2 bolts
      Fig 19: Identifying Front Door Front Lower Frame Sub-Assembly With Bolts
      G05321240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run
      Fig 20: Identifying Front Door Glass Run
      G05321200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION 
    1. Install the front No. 1 door stiffener cushion with the 2 bolts and double-sided tape.
    Fig 21: Identifying Front No. 1 Door Stiffener Cushion With Bolts
    G05321199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.
    1. Using a "TORX" socket wrench (T25), install the front power window regulator motor assembly with the 3 screws.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      HINT:

      A new front window regulator uses self-tapping screws to thread new installation holes when inserted.

      Fig 22: Locating Front Power Window Regulator Motor Assembly And Screws
      G05321198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts on the front door window regulator sub-assembly.
    2. Install the temporary bolt to the front door window regulator sub-assembly.
    3. Temporarily install the window regulator in the door.
    4. Tighten the temporary bolt and 5 bolts in the order shown in the illustration to install the front window regulator.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      Fig 23: Identifying Front Door Window Regulator Sub-Assembly
      G05756045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Connect the cable to the negative (-) battery terminal and the front power window regulator motor connector.
    2. 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.
    3. Disconnect the power window regulator master switch assembly and the front power window regulator motor connector
    4. Disconnect the cable from the negative (-) battery terminal
    5. 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 illustration.
      Fig 24: Inserting Front Door Glass Sub-Assembly Into Front Door Panel
      G05756046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the front door glass sub-assembly with the 2 bolts

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 25: Identifying Front Door Glass Sub-Assembly With Bolt
      G05321195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the hole plug
  29. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Apply butyl tape to the front door panel
    2. Pass the front door lock remote control cable and front door inside locking cable through a new front door service hole cover.
      Fig 26: Identifying Front Door Glass Sub-Assembly
      G05321194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the front door service hole cover according to the reference points on the front door panel.
      NOTE: Securely install the front door service hole cover preventing wrinkles and air bubbles.
      Fig 27: Identifying Reference Points On Front Door Panel
      G05756049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage each clamp.
    5. Connect each connector.
  30. INSTALL OUTER MIRROR CONTROL ECU  (See INSTALLATION )
  31. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY  (See INSTALLATION )
  32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY  (See INSTALLATION )
  33. INSTALL DOOR FRAME GARNISH 
    1. Install the door frame garnish with the 2 clips.
      Fig 28: Identifying Door Frame Garnish And Clips
      G05321191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FRONT DOOR TRIM COVER 
    1. Engage the 6 clips to install the front door trim cover.
    2. Install the screw.
      Fig 29: Identifying Front Door Trim Cover Screws
      G05321190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 4 claws and install the front door inner glass weatherstrip
    Fig 30: Identifying Front Door Inner Glass Weatherstrip Claws
    G05321252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL SEAT MEMORY SWITCH  (See INSTALLATION )
  37. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Install the front door inside handle sub-assembly with the 4 screws
      Fig 31: Identifying Front Door Inside Handle Sub-Assembly And Screws
      G05321189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bracket with the 3 screws
    Fig 32: Identifying Bracket Screws
    G05321188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY  (See INSTALLATION )
  39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Install 2 new front door trim board retainers (green).
    2. Connect the front door lock remote control cable and front door inside locking cable to the front inside handle
    3. Connect each connector
      Fig 33: Connecting Front Door Lock Remote Control Cable And Front Door Inside Locking Cable
      G05321255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the front door trim board with the 4 clips of the front door inner glass weatherstrip.
      Fig 34: Identifying Front Door Trim Board With Clips
      G05756056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Engage the 9 clips and install the front door trim board to the front door panel.
      Fig 35: Identifying Front Door Trim Board Sub-Assembly Clips
      G05321184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 2 screws.
  40. INSTALL COURTESY LIGHT ASSEMBLY 
    1. Connect the connector.
    2. Engage the claw and install the courtesy light assembly.
    Fig 36: Identifying Courtesy Light Assembly Claw
    G05321183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL 
    1. Connect each connector.
    2. Engage the 4 claws and 2 clips, and install the power window regulator master switch assembly with front door armrest base panel.
      Fig 37: Identifying Power Window Regulator Master Switch Assembly With Front Door Armrest Base Panel
      G05320718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws and install the front door inside handle bezel plug
    Fig 38: Identifying Front Door Inside Handle Bezel Plug And Claws
    G05321260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  44. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    (See INITIALIZATION )

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