Front Door: Reassembly

1. Install the 2 cushions.
   Fig 1: Identifying Cushions

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HINT:

Use the same procedure as for the LH side (see INSTALLATION ).

1. Using "Torx" socket wrench T30, install the front door outside handle frame with the screw.

   Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

   NOTE: A cover should be inserted between the nut and the door panel.
   Fig 2: Identifying Front Door Outside Handle Frame Sub-Assembly

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1. Engage the 3 claws and install the front door outside handle front pad.
   Fig 3: Identifying Front Door Outside Handle Front Pad Claws

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1. Engage the 2 claws and install the front door outside handle rear pad.
   Fig 4: Identifying Front Door Outside Handle Rear Pad Claws

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1. While pushing the front door outside handle in the direction of the arrow mark shown in Fig 5, install the front door outside handle.

1. Engage the 2 claws and install the front door outside handle cover.
   Fig 6: Identifying Front Door Outside Handle Cover Claws

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2. Using "Torx" socket wrench T30, install the cover with the door lock key cylinder.

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

   HINT:

   Make sure that the door lock key cylinder rod is inserted.

3. Install the hole plug.
   Fig 7: Identifying Cover With Door Lock Key Cylinder

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1. Apply MP grease to the sliding and rotating areas of the front door window regulator.
   NOTE: Do not apply grease to the window regulator spring.
2. Install the front door window regulator with the 6 bolts.

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

   NOTE: Do not drop the window regulator as it may be damaged.
3. Connect the connector.
   Fig 8: Identifying Front Door Window Regulator Sub-Assembly Bolts

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1. Install the front door glass onto the front door window regulator with the 2 bolts.

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

   NOTE: Do not damage the glass.
   Fig 9: Identifying Front Door Glass Sub-Assembly Bolts

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2. Install the hole plug.
   Fig 10: Identifying Hole Plug

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1. Install the front door window frame rear lower, and temporarily tighten the bolt.
   Fig 11: Identifying Front Door Window Frame Rear Lower Bolt

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1. Install the front door lower frame bracket garnish with the bolt and 2 screws.

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

   Fig 12: Identifying Front Door Lower Frame Bracket Garnish Bolt & Screws

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1. Install the front door frame sub-assembly front lower with the screw.
2. Temporarily tighten the bolt.
   Fig 13: Identifying Front Door Frame Sub-Assembly Front Lower Screw & Bolt

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1. Install the front door glass run.
   Fig 14: Identifying Front Door Glass Run

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2. Tighten the front door window frame rear lower to the specified torque with the bolt.

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

   Fig 15: Identifying Front Door Window Frame Rear Lower Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten the front door frame sub-assembly front lower to the specified torque with the bolt.

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

   Fig 16: Identifying Front Door Frame Sub-Assembly Front Lower Bolt

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4. Install the hole plug.
   Fig 17: Identifying Hole Plug

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1. Install the front door weatherstrip.
   Fig 18: Identifying Front Door Weatherstrip Clips

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1. Apply MP grease to the sliding areas of the door check.
2. Install the front door check onto the door panel with the 2 nuts.

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

3. Apply adhesive to the threads of the bolt.

   Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or the equivalent. 

4. Install the front door check onto the body panel with the bolt.

   Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

   Fig 19: Identifying Front Door Check Nuts & Bolt

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1. Install the front door inside panel plate with the 4 screws.
   Fig 20: Identifying Front Door Inside Panel Plate Screws

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1. Apply butyl tape to the door panel, then install the new front door service hole cover.
   Fig 21: Identifying New Front Door Service Hole Cover

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   HINT:

   • When installing the service hole cover, pull the links out through 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.

HINT:

Use the same procedure as for the LH side (See INSTALLATION ).

HINT:

Use the same procedure as for the LH side (See INSTALLATION ).

1. Install the front No. 2 door service hole cover with the 4 screws.
   Fig 22: Identifying Front No. 2 Door Service Hole Cover Screws

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1. Connect the front door lock remote control cable and front door inside locking cable.
   Fig 23: Identifying Front Door Lock Remote Control Cable & Inside Locking Cable

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2. Engage the 10 clips and install the front door trim board.
   Fig 24: Identifying Front Door Trim Board Sub-Assembly Clips

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3. Tighten the 2 screws.
   Fig 25: Identifying Front Door Trim Board Sub-Assembly Screws

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4. for LH side.

   Close the 2 covers.

   Fig 26: Closing Covers (For LH Side)

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5. for RH side:

   Close the 2 covers.

   Fig 27: Closing Covers (For RH Side)

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1. Connect the connector.
2. Engage the 3 claws and clip and install the front armrest base upper panel.
   Fig 28: Identifying Front Armrest Base Upper Panel Claws

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Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)