LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2018 >> LC 500 >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Door / Hatch - Service Information (Coupe) (1 Of 2) >> Front Door >> Reassembly [03/2017 - 06/2019] >> Procedure

Reassembly [03/2017 - 06/2019]: Procedure

  1. INSTALL STEP PANEL WIRE LH 
    1. Attach the clamp to install the step panel wire LH.
  2. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP LH 
    1. Remove the peeling paper from the face of a new front door No. 2 weatherstrip LH.

      HINT: 

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

    2. Attach the grommet and double-sided tape.
      GTY822295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Grommet
      Double-sided Tape
    3. Attach the clips to install the front door No. 2 weatherstrip LH.

      HINT: 

      Press the front door No. 2 weatherstrip LH firmly to install it.

  3. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  4. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY LH 
    1. Put the outside door handle in the full stroke position and install the front door lock cylinder assembly LH.
    2. Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly LH with the "TORX" screw.

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

  5. INSTALL OUTSIDE DOOR HANDLE SUB-ASSEMBLY LH 
    1. Apply MP grease to the sliding area of the outside door handle sub-assembly LH.
    2. Temporarily install the outside door handle sub-assembly LH with the 4 bolts.
    3. Tighten the 4 bolts in the order shown in the illustration to install the outside door handle sub-assembly LH.
      Fig 1: Outside Door Handle Sub-Assembly LH Tightening Sequence
      GTY802667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Connector

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

      NOTE:

      When tightening the handle, check there is no significant gaps or differences.

    4. Connect the 4 connectors and attach the clamp.
    5. Remove the protective tape.
  6. INSTALL FRONT DOOR PANEL CUSHION 
    1. Attach the claws to install a new front door panel cushion.
      GTY829466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL HOLE PLUG 
    1. for Front Door Inside Panel Side:

      Install the 2 hole plugs.

      GTY785122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Front Door Outer Panel Side:

      Install the hole plug.

      GTY785124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DOOR WIRE LH 
    1. Attach the clamps to install the front door wire LH.
      GTY786807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH 
    1. Using a 4.0 mm hexagon wrench, adjust the 2 stud bolts at the bottom of the front door window regulator assembly LH as shown in the illustration.
      GTY781513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      Area Specified Condition
      A 20.9 to 21.9 mm (0.823 to 0.862 in.)
    2. Apply MP grease to the sliding and rotating areas of the front door window regulator sub-assembly LH.
    3. Temporarily install the front door window regulator assembly LH with the 7 nuts.
      GTY784436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
      Connector
    4. Connect the connector.
    5. Tighten the 2 nuts <A> and 3 nuts <B>.
      GTY791437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut <A>
      Nut <B>

      Nut <A> 

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

      Nut <B> 

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

  10. INSTALL FRONT DOOR GLASS RUN LH 
    1. Install the front door glass run LH for the front door front lower frame sub-assembly LH.
      NOTE:

      Make sure the hole on the end of the front door glass run LH is fitted securely to the protrusion on the lower part of the front door front lower frame sub-assembly LH.

  11. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH 
    1. Install the front door front lower frame sub-assembly LH with the 2 nuts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  12. INSTALL FRONT DOOR UPPER WINDOW STOP 
    1. Temporarily install the 2 front door upper window stops.
      GTY786524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH 
    1. Slide the front door glass sub-assembly LH in the direction of the arrows shown in the illustration and install it to the carrier plate of the front door window regulator sub-assembly LH.
      GTY801412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
    2. Install the front door glass sub-assembly LH with the 3 nuts.
      GTY786778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Tighten the 2 bolts to install the 2 front door upper window stops.

      Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf) 

      GTY829771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the front door glass sub-assembly LH.

    4. Lift up the front door glass sub-assembly LH and install the door window female stabilizer LH with the bolt.
      GTY775920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Move in this Direction
      Bolt

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

    5. Install the 2 window regulator shims.
      GTY786780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the 2 nuts to install the front door window regulator sub-assembly LH.
      GTY786792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    7. Install the 5 hole plugs.
      GTY786777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR CHECK ASSEMBLY LH 
    1. Apply MP grease to the sliding areas of the front door check assembly LH.
    2. Install the front door check assembly LH with the 2 nuts.

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

  15. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY LH 

    Refer to PROCEDURE - Step 4

  16. INSTALL FRONT DOOR INSIDE PANEL SUB-ASSEMBLY LH 
    NOTE:
    • Although CFRP material has high strength, there is a possibility of cracking if an excessive load is applied. As a result, pay attention to how it is handled.
    • Perform this operation with 2 or more people because of the risk of deformation or damage.
    • Be careful not to damage the front door glass sub-assembly LH.
    • There are limited gaps between the end of the bolts and the door outer panel and readjusting the threading by tapping is difficult. As a result, the front door inside panel sub-assembly LH installation bolts and "TORX" screw ((7) and (8) in the illustration) should only be temporarily installed as not to damage the threads.
    1. Attach the center door guide piece on the front door panel sub-assembly LH of the arrow shown in the illustration.
      GTY810394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Temporarily install the "TORX" bolt, 7 "TORX" screws and 3 front door inside plates.
    3. Temporarily install the 4 bolts.
    4. Fig 2: Front Door Inside Plate Tightening Sequence
      GTY817458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      "TORX" screw
      Bolt
      "TORX" bolt
      (w/ Rubber Cushion)
      Front Door Inside Panel Plate
      ("TORX" screw)

      Tighten the bolt, "TORX" bolt, "TORX" screw and front door inside plate in the order shown in the illustration.

      1. "TORX" screw:

        Using a T30 "TORX" socket wrench, tighten the 7 "TORX" screws.

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

      2. Bolt:

        Tighten the 4 bolts.

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

      3. "TORX" bolts (w/ Rubber Cushion)

        Using a T30 "TORX" socket wrench, tighten the "TORX" bolts.

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

      4. Front door inside panel plate:

        Using a T30 "TORX" socket wrench, tighten the 3 front door inside panel plates.

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

    5. Attach the clamps.
      GTY786775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the connector.
      GTY831426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Close in this Direction
    7. Close the wiring protector and attach the claw.
    8. Connect the 2 connectors and install the grommet.
      GTY800498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Grommet
      Connector
    9. GTY786782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the front door wire harness connector and attach the claws.

    10. Clean the bolt hole on the vehicle body.
    11. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

    12. Install the bolt.
      GTY786781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    13. Insert your hand into the service hole, attach the door lock side rod and install the snap lock.
      GTY808103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  17. INSPECT FRONT DOOR GLASS SUB-ASSEMBLY LH 
    1. Check that the clearance measurements of areas a through m are within each standard range.
      GTY786815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      Area Measurement Area Measurement
      A
      (Reference)      		 15.0 mm (0.591 in.) B 3.1 to 7.1 mm (0.122 to 0.280 in.)
      C 8.7 to 12.7 mm (0.343 to 0.500 in.) D
      (Reference)      		 15.0 mm (0.591 in.)
      E 3.2 to 7.2 mm (0.126 to 0.283 in.) F 8.5 to 12.5 mm (0.335 to 0.492 in.)
      G
      (Reference)      		 15.0 mm (0.591 in.) H 3.2 to 7.2 mm (0.126 to 0.283 in.)
      I 7.6 to 11.6 mm (0.299 to 0.457 in.) J 10.0 to 14.0 mm (0.394 to 0.551 in.)
      K
      (Reference)      		 0 mm (0 in.) L 10.0 to 14.0 mm (0.394 to 0.551 in.)
      M
      (Reference)      		 0 mm (0 in.) - -
  18. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY LH 
    1. Adjust the fit of the top part of the front door glass sub-assembly LH inward and outward.
      GTY786836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Loosen the 2 nuts at the bottom of the front door window regulator assembly LH.
      2. Using a 4.0 mm hexagon wrench, turn the 2 stud bolts to adjust the fit of the top part of the front door glass sub-assembly LH inward and outward.

        HINT: 

        When the stud bolt are turned counterclockwise, the top part of the front door glass sub-assembly LH moves toward the inside of the vehicle. When the stud bolt are turned clockwise, the top part of the front door glass sub-assembly LH moves toward the outside of the vehicle.

      3. Tighten the 2 nuts after adjustment.

        Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    2. Adjust the fit of the bottom part of the front door glass sub-assembly LH inward and outward.
      GTY786780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Loosen the 2 nuts at the top of the front door window regulator assembly LH.
      2. Change the number of installed window regulator shims to adjust the fit of the bottom part of the front door glass sub-assembly LH inward and outward.

        HINT: 

        • When more shims are used, the bottom part of the front door glass sub-assembly LH moves toward the outside of the vehicle. When less shims are used, the bottom part of the front door glass sub-assembly LH moves toward the inside of the vehicle.
        • The thickness of one window regulator shim is 1.0 mm (0.039 in.).
      3. Tighten the 2 nuts after adjustment.

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

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

      Refer to PROCEDURE - Step 2

    4. for Driver Side:

      Connect the No. 2 front door wire LH, multiplex network master switch assembly and front door multiplex network ECU LH connectors.

    5. for Front Passenger Side:

      Connect the No. 2 front door wire RH, power window regulator switch assembly and front door multiplex network ECU RH connectors.

    6. Adjust the front door glass sub-assembly LH fully closed position horizontally and vertically.
      GTY824320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Front Door Upper Window Stop
      Nut
      1. Loosen the 2 front door upper window stop bolts and temporarily move the front door upper window stops to the top of their adjustment range and then temporarily tighten the bolts.
      2. Loosen the 3 front door glass sub-assembly LH nuts.
      3. Stop the front door glass sub-assembly LH approximately 3 mm (0.118 in.) below the fully closed position.
      4. While holding the front door glass sub-assembly LH, move it vertically and horizontally to adjust its position.
      5. Tighten the 3 nuts after adjustment.

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

      6. Move the front door glass sub-assembly LH to the fully closed position.
      7. Loosen the 2 front door upper window stop bolts.
      8. While lightly pushing each front door upper window stop against the stopper on the front door glass sub-assembly, tighten each bolt.

        Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf) 

    7. Disconnect the cable from the negative (-) battery terminal.

      Refer to PROCEDURE - Step 2

      WARNING:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

      GTY581108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

      Refer to INITIALIZATION [03/2017 - 04/2020]

    8. for Driver Side:

      Disconnect the No. 2 front door wire LH, multiplex network master switch assembly and multiplex network front door ECU LH connector.

    9. for Front Passenger Side:

      Disconnect the No. 2 front door wire RH, power window regulator switch assembly and multiplex network front door ECU RH connector.

  19. INSTALL REAR ACCESS PANEL WEATHERSTRIP LH 
    1. Remove the peeling paper from the face of a new rear access panel weatherstrip LH.
    2. Attach the double-sided tape.
      GTY779087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clip <A>
      Double-sided Tape
    3. Install the clip <A>.
    4. Attach the clips to install the rear access panel weatherstrip LH.

      HINT: 

      Press the rear access panel weatherstrip LH firmly to install it.

  20. INSTALL FRONT DOOR TRIM SEAL LH 
    1. Attach the clips to install the front door trim seal LH.
      GTY786789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FRONT DOOR WEATHERSTRIP LH 
    1. Remove the peeling paper from the face of a new front door weatherstrip LH.
    2. Attach the double-sided tape.
      GTY806767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-sided Tape
    3. Attach the clips to install the front door weatherstrip LH.

      HINT: 

      Press the front door weatherstrip LH firmly to install it.

  22. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP LH 
    1. Install the front door No. 3 weatherstrip LH with the 3 clips.
      GTY786787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DOOR DIVISION BAR SEAL LH 
    1. Install the front door division bar seal LH with the 2 clips.
      GTY786786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER LH 

    Refer to PROCEDURE - Step 1

  25. INSTALL DOOR SIDE AIRBAG SENSOR LH 

    Refer to PROCEDURE - Step 1

  26. INSTALL NO. 1 FRONT DOOR HOLE COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  27. INSTALL FRONT DOOR MULTIPLEX NETWORK ECU LH 
    1. Install the front door multiplex network ECU LH with the 2 screws.
      GTY789373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Screw
      Connector
    2. Connect the 3 connectors.
  28. INSTALL NO. 1 SPEAKER ASSEMBLY WITH BOX 

    Refer to PROCEDURE - Step 1

  29. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
    1. Attach the clips to install the front door lower frame bracket garnish LH.
      GTY786825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  31. INSTALL NO. 2 FRONT DOOR WIRE LH 
    1. Connect the connector and attach clamps to install the No. 2 front door wire LH.
  32. INSTALL SEAT MEMORY SWITCH (for Driver Side) 

    Refer to PROCEDURE - Step 1

  33. INSTALL INDICATOR LIGHT COVER 

    Refer to PROCEDURE - Step 1

  34. INSTALL INDICATOR LIGHT BRACKET 

    Refer to PROCEDURE - Step 2

  35. INSTALL INDICATOR LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 3

  36. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH 
    1. Bend the claws as shown in the illustration and install the front door inner glass weatherstrip LH to the front door trim board sub-assembly LH.
      GTY786516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH 
    1. Install the front door inside handle sub-assembly LH with the 4 screws.
  38. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side) 

    Refer to PROCEDURE - Step 1

  39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH (for Driver Side) 
    1. Connect the connector.
      GTY786826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY829841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the front door lock remote control cable assembly LH for the front door inside handle sub-assembly LH.

    3. Insert the front door trim board sub-assembly LH into the front door panel to set the front door panel sub-assembly LH.
      GTY823419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    4. Attach the clips to install the front door trim board sub-assembly LH.
    5. Install the 2 screws.
      GTY829824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL COURTESY LIGHT ASSEMBLY LH (for Driver Side) 

    Refer to PROCEDURE - Step 1

  41. INSTALL FRONT DOOR TRIM COVER SUB-ASSEMBLY LH (for Driver Side) 
    1. Attach the clips to install the front door trim cover sub-assembly LH.
  42. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) 

    Refer to PROCEDURE - Step 1

  43. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY RH (for Front Passenger Side) 
    1. Connect the connector.
      GTY786977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY786761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the front door lock remote control cable assembly RH for the front door inside handle sub-assembly RH.

    3. Insert the front door trim board sub-assembly RH into the front door panel to set the front door panel sub-assembly RH.
      GTY778097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    4. Attach the clips to install the front door trim board sub-assembly RH.
    5. Install the 3 screws.
  44. INSTALL COURTESY LIGHT ASSEMBLY RH (for Front Passenger Side) 

    Refer to PROCEDURE - Step 1

  45. INSTALL FRONT DOOR ASSIST GRIP ASSEMBLY RH (for Front Passenger Side) 
    1. Attach the clips to install the front door assist grip assembly RH.
  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [03/2017 - 04/2020]

  47. INSTALL NO. 2 DECK BOARD 

    Refer to PROCEDURE - Step 13

  48. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    Refer to INITIALIZATION [03/2017 - ]

  49. INSPECT POWER WINDOW OPERATION 

    Refer to OPERATION CHECK [03/2017 - ]

  50. CHECK SRS WARNING LIGHT 

    Refer to OPERATION CHECK [03/2017 - 04/2020]

  51. INSPECT DOOR LOCK OPERATION 

    Refer to OPERATION CHECK [03/2017 - ]

scientia non olet · About LEMON Manuals