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Front Door: Reassembly

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

  1. INSTALL CUSHION 
    1. Install the 2 cushions.
  2. INSTALL FRONT DOOR WEATHERSTRIP LH 
    1. Attach the 17 clips to install the weatherstrip.
      Fig 1: Attaching Clips To Weatherstrip
      G04492057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT DOOR GLASS RUN LH 
  4. INSTALL FRONT DOOR CHECK ASSEMBLY LH 
    1. Apply MP grease to the sliding areas of the door check (see Fig 2).
    2. Install the door check to the door panel with the 2 bolts.

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

    3. Apply adhesive to the bolt.

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

    4. Install the door check to the body panel with the bolt.

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

      Fig 2: Installing Door Check To Body Panel With Bolt
      G04492058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DOOR OUTSIDE HANDLE FRONT PAD 
    1. Attach the 2 claws to install the pad.
      Fig 3: Attaching Claws Front Door Outside Handle Front Pad
      G04492059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DOOR OUTSIDE HANDLE REAR PAD 
    1. Attach the 2 claws to install the pad.
      Fig 4: Attaching Claws And Front Door Outside Handle Rear Pad
      G04492060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH 
    1. Install the front door lock open rod.
    2. Attach the claw and clip to install the frame.
      Fig 5: Attaching Claw And Clip To Frame
      G04492061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a T30 "Torx" socket, install the screw.

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

      Fig 6: Tightening Screw
      G04492062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH 
    1. Install the handle by pushing and sliding it in the direction indicated by the arrows in the illustration.
      2. Fig 7: Installing Front Door Outside Handle Assembly
      G04492063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL FRONT DOOR LOCK ASSEMBLY LH 
    1. Apply MP grease to the sliding and rotating areas of the front door lock.
    2. Install the 2 cables as shown in the illustration.
      Fig 8: Installing Cables
      G04492064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the 3 claws to close the cover.
      Fig 9: Attaching Claws To Close Cover
      G04492065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new door lock wire harness packing (see Fig 10).
      NOTE:
      • When reinstalling the door lock, always use new packing.
      • Do not allow grease or dirt to contaminate the gap between the door panel and packing.
      • Old or damaged packing cannot effectively protect against water which can damage the door lock.
        Fig 10: Installing Door Lock Wire Harness Packing
        G04492066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the control rod to the door lock, and then set it to the door panel.
      NOTE: Make sure that the rod is securely engaged to the lock.
      Fig 11: Connecting Control Rod To Door Lock, And Then Set It To Door Panel
      G04492067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Apply adhesive to the threads of the 3 screws.

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

    7. Using a T30 "Torx" socket, install the door lock with the 3 screws.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 12: Installing Door Lock
      G04492068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the connector.
  10. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (for Driver Side) 
    1. Install the door lock cylinder to the cover.
    2. Using a T30 "Torx" socket, install the cover (with cylinder) with the screw.

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

      HINT:

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

    3. Install the hole plug.
      Fig 13: Installing Front Door Outside Handle Cover (Driver Side)
      G04492069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (for Front Passenger Side) 
    1. Using a T30 "Torx" socket, install the cover with the screw.

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

    2. Install the hole plug.
      Fig 14: Installing Front Door Outside Handle Cover (Front Passenger Side)
      G04492070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT DOOR REAR LOWER FRAME SUBASSEMBLY LH 
    1. Install the frame with the bolt.

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

      Fig 15: Installing Front Door Rear Lower Frame
      G04492071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH 
    1. Using a T25 "Torx" driver, install the motor with the 3 screws.

      Torque: 5.4 N*m (55 kgf*cm, 49 in.*lbf) 

      Fig 16: Installing Power Window Regulator Motor Assembly
      G04492072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR WINDOW REGULATOR SUBASSEMBLY LH 
    1. Apply MP grease to the sliding and rotating areas of the window regulator.
      NOTE: Do not apply grease to the spring of the window regulator.
      Fig 17: Applying MP Grease To Sliding And Rotating Areas Of Window Regulator
      G04492073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the regulator with the 6 bolts.

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

      NOTE: Be careful not to drop the window regulator as it may became damaged.
      Fig 18: Installing Window Regulator
      G04492074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector.
  15. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH 
    1. Install the door glass into the door panel along the glass run as indicated by the arrows in Fig 19.
      NOTE: Be careful not to damage the glass.
      Fig 19: Installing Door Glass Into Door Panel
      G04492075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the door glass to the window regulator with the 2 bolts.

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

      Fig 20: Installing Door Glass To Window Regulator
      G04492076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY LH (See appropriate step(s) under  REMOVAL  ) 
  17. INSTALL FRONT DOOR SERVICE HOLE COVER LH 
    1. Apply butyl tape to the door panel, then install a new front door service hole cover as shown in Fig 21.

      HINT:

      • When installing the service hole cover, pull out the links and connectors through the service hole cover.
      • There should be no wrinkles or folds after attaching the service hole cover.
      • After attaching the service hole cover, check the sealing quality.
      Fig 21: Installing Front Door Service Hole Cover
      G04492077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect each connector.
  18. INSTALL FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH 
    1. Connect the 2 cables to the inside handle.
      2. Fig 22: Connecting Cables To Inside Handle
      G04492078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (See appropriate step(s) under  INSTALLATION  ) 
  20. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY (See appropriate step(s) under  INSTALLATION  ) 
  21. INSTALL OUTER REAR VIEW MIRROR SUBASSEMBLY LH (See appropriate step(s) under  OUTER REAR VIEW MIRROR  ) 
  22. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH 
    1. Attach the 4 claws to install the speaker door grille.
    2. Attach the 7 claws to install the weatherstrip inner.
    3. Attach the 2 claws to install the inside handle.
      Fig 23: Attaching Claws To Inside Handle
      G04492079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Attach the 10 clips to install the trim board.
    5. Install the 3 screws.
      Fig 24: Attaching Clips To Trim Board
      G04492080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Attach the 3 claws to install the door inside handle bezel plug.
      Fig 25: Attaching Claws To Door Inside Handle Bezel Plug
      G04492081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Attach the 12 claws to install the door assist grip.
      Fig 26: Attaching Claws To Door Assist Grip
      G04492082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT ARMREST BASE PANEL UPPER LH 
    1. for Driver Side: Install the power window regulator master switch to the panel with the 3 screws.
      Fig 27: Installing Power Window Regulator Master Switch To Panel With Screws
      G04492083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Passenger Side: Attach the 2 claws and install the power window regulator switch to the panel.
      Fig 28: Attaching Claws And Power Window Regulator Switch To Panel
      G04492084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. for Passenger Side: Attach the 2 claws and install the door control switch to the panel.
      Fig 29: Attaching Claws And Door Control Switch To Panel
      G04492085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the switch connectors.
    5. Attach the clip and 5 claws to install the panel (with the switch).
      Fig 30: Attaching Clip And Claws To Panel (With Switch)
      G04492086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH 
    1. Attach the clip and 3 claws to install the garnish.
      Fig 31: Attaching Clip And Claws To Garnish
      G04492087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
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