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Front Door: Reassembly

  1. INSTALL FRONT DOOR BELT MOLDING ASSEMBLY 
  2. INSTALL FRONT DOOR WEATHERSTRIP 
  3. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Install the front door check assembly with the 3 bolts.

      Torque: door side 

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

      Torque: body side 

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

      Fig 1: Identifying Front Door Check Assembly With 3 Bolts
      G05244172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply body grease to the sliding parts on the front door outside handle frame sub-assembly.
    2. Engage the clip.
      Fig 2: Identifying Clip
      G05244171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the claw.
      Fig 3: Identifying Claw
      G05244170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. 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) 

      Fig 4: locating Front Door Outside Handle Frame Sub-Assembly With Screw
      G05244169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR 
  6. INSTALL FRONT DOOR OUTSIDE HANDLE PAD 
  7. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE 
  8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER 
    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) 

      Fig 5: Identifying Front Door Outside Handle Cover And Screw
      G05205463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT DOOR LOCK ASSEMBLY 
    NOTE:
    • When reusing the removed front door lock assembly, replace the door lock wire harness sealing on the connector with a new one.
    • Do not adhere grease or dust to the door lock wire harness sealing surface of the connector.
    • Reusing the door lock wire harness sealing and/ or using damaged door lock wire harness sealing may cause water intrusion to the connection, and result in a malfunction of the front door lock assembly.
    1. Apply body grease to the sliding parts on the front door lock assembly.
    2. Insert the front door outside handle link rods to the front door lock assembly, and set to front door panel.
      Fig 6: Identifying Front Door Outside Handle Link Rods To Front Door Lock Assembly
      G05244163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Make sure that the front door outside handle link is securely connected to the front door lock assembly.
    4. Using a "Torx" socket wrench (T30), install the front door lock assembly with the 3 screws.

      Torque: 5.0 N*m (51 kgf*cm, 42 in.*lbf) 

    5. Install the bolt.

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

    6. Connect the connector.
  10. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER 
  11. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT 
    NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.
    1. Using a "Torx" driver (T25), install the power window regulator motor sub-assembly front with the 3 screws.

      HINT:

      The new front window regulator adopts a self-tapping method. The installation position of regulator will be threaded when the self-tapping screw is inserted.

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

      Fig 7: Locating Front Door Window Regulator Sub-Assembly
      G04981725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Apply body 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.
      Fig 8: Identifying Temporary Bolt To Front Door Window Regulator Sub-Assembly
      G05244160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily install the window regulator.
    4. Install the front door window regulator sub-assembly with the 6 bolts.

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

    5. Connect the connector.
  13. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Install the front door glass sub-assembly with the 2 bolts.

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

      Fig 9: Identifying Front Door Glass Sub-Assembly With Bolts
      G05244159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR GLASS RUN 
  15. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Apply butyl tape to the front door panel, as shown in the illustration.
      2. Fig 10: Applying Butyl Tape To Front Door Panel
      G05244186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new front door service hole cover.
  16. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY  (See INSTALLATION )
  17. INSTALL FRONT NO.2 SPEAKER  (See INSTALLATION )
  18. INSTALL FRONT NO.1 SPEAKER  (See REMOVAL )
  19. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Connect the 2 cables.
    2. Engage the 2 claws.
    3. Install the front door inside handle sub-assembly with the bolt.

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

      Fig 11: Identifying Front Door Inside Handle Assembly
      G05244157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
  21. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH 
  22. INSTALL DOOR PULL HANDLE 
  23. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY 
  24. INSTALL FRONT DOOR INSIDE HANDLE BEZEL 
    1. Install the front door inside handle bezel with the screw and the 3 claws.

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

  25. POWER WINDOW CONTROL SYSTEM INITIALIZATION 

    (See INITIALIZATION )

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