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FRONT DOOR (for Hatchback without Power Window): Reassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL FRONT DOOR STIFFENER CUSHION 
    1. Install the front door stiffener cushion with the bolt.

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

  2. INSTALL CUSHION 
    1. Install the cushion onto the door panel.
      Fig 1: Locating Front Door Stiffener Cushion Bolt
      G04834690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Using "Torx" socket wrench T30, install the front outside handle frame with the screw.

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

      Fig 2: Locating Front Door Outside Handle Frame
      G04834698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT DOOR OUTSIDE HANDLE PAD FRONT 
    1. Engage the 2 claws and install the front door outside handle pad front.
      Fig 3: Identifying Claws Location (1 Of 2)
      G04834688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR 
    1. Engage the 2 claws and install the front door outside handle pad rear.
      Fig 4: Identifying Claws Location (2 Of 2)
      G04834687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE 
    1. Pushing the front door handle assembly outside in the direction of the arrow mark shown in Fig 5, install the front door handle assembly outside.
  7. INSTALL FRONT DOOR LOCK ASSEMBLY 
    NOTE:
    • If reusing a door lock that has been removed, replace the packing in the connecting part with new.
    • Make sure that no grease and dirt adheres to the packing surface in the connecting part.
    1. Apply MP grease to the sliding and rotating areas of the front door lock.
      Fig 5: Pushing Front Door Handle
      G04834773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the front door lock remote control cable and front door inside locking cable.
      Fig 6: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable
      G04834601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the 5 claws and close the cover.
      Fig 7: Locating Cover
      G04834600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Insert the door lock open rod into the front door lock, then set it to the door panel.
      NOTE: Make sure that the outside handle link is securely engaged with the door lock.
      Fig 8: Inserting Door Lock Open Rod Into Front Door Lock
      G04834627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply adhesive to the threads of the screws.

      Adhesive: 

      Part No. 08833-00070, THREE BOND 1324 or the equivalent 

    6. Using "Torx" socket wrench T30, install the front door lock with the 3 screws.

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

      Fig 9: Locating "Torx" Screws
      G04834683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER 
    1. Using "Torx" socket wrench T30, install the cover with the door lock key cylinder.

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

      HINT:

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

    2. Install the hole plug.
  9. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP 
    1. Install the front door fix window glass onto the front door fix window weatherstrip.
      Fig 10: Identifying Door Lock Key Cylinder
      G04834754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the front door fix window weatherstrip, in the direction indicated by the arrow in Fig 11, to install it.
      Fig 11: Sliding Front Door Fix Window Weatherstrip
      G04834707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER 
    1. Install the front door frame sub-assembly front lower with the 2 bolts and screw.

      Torque: 6.2 N*m (63 kgf*cm, 54 in.*lbf) 

      Fig 12: Locating Front Door Frame Sub-Assembly Front Lower Bolts
      G04834680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER 
    1. Install the front door frame sub-assembly rear lower with the bolt.

      Torque: 6.2 N*m (63 kgf*cm, 54 in.*lbf) 

      Fig 13: Locating Front Door Frame Sub-Assembly Rear Lower Bolt
      G04834679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL FRONT DOOR WEATHERSTRIP 
    1. for 5 Door:

      Engage the 35 clips and install the front door weatherstrip.

      Fig 14: Identifying Clips Location (5 Door)
      G04834677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for 3 Door:

      Engage the 37 clips and install the front door weatherstrip.

      Fig 15: Identifying Clips Location (3 Door)
      G04834678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT DOOR CHECK ASSEMBLY 
    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 bolts.

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

    3. Apply adhesive to the threads of the bolt.

      Adhesive: 

      Part No. 08833-00070, 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 16: Locating Front Door Check Bolts
      G04834676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR WINDOW REGULATOR 
    1. Apply MP grease to the sliding and rotating areas of the front door window regulator sub-assembly.
      NOTE: Do not apply grease to the window regulator spring.
    2. Loosely screw bolt A onto the front door window regulator sub-assembly.
    3. Insert the front door window regulator into the door panel. Use bolt A to hang the front door window regulator on the door panel.
      NOTE: Do not drop the window regulator as it may be damaged.
    4. Install the front door window regulator with the 4 bolts, and tighten bolt A.

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

      Fig 17: Locating Front Door Window Regulator & Bolts
      G04834747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      Fig 18: Locating Front Door Glass Run
      G04834673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Insert the door glass into the door panel along the glass run as indicated by the arrows.
      NOTE: Do not damage the glass.
      Fig 19: Inserting Door Glass Into Door Panel
      G04834716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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) 

      Fig 20: Locating Bolts
      G04834671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. for 5 Door:

      Apply butyl tape to the door panel, then install the front door service hole cover as shown in Fig 21 .

      Adhesive: 

      Part No. 08850-00065, Butyl Tape Set or the equivalent 

      Specification 

      AREA DIMENSION TABLE

      Area Dimension
      A 2.0 mm (0.079 in.) or more
      B 6.0 mm (0.236 in.) or more

      HINT:

      • When installing the service hole cover, pull the links and connectors out through the 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.
        Fig 21: Identifying Front Door Service Hole Cover (5 Door)
        G04834718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for 3 Door:

      Apply butyl tape to the door panel, then install the front door service hole cover as shown in Fig 22 .

      Adhesive: 

      Part No. 08850-00065, Butyl Tape Set or the equivalent 

      Specification 

      AREA DIMENSION TABLE

      Area Dimension
      A 2.0 mm (0.079 in.) or more
      B 6.0 mm (0.236 in.) or more

      HINT:

      • When installing the service hole cover, pull the links and connectors out through the 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.
        Fig 22: Identifying Front Door Service Hole Cover (3 Door)
        G04834719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FRONT DOOR BELT MOLDING (See  INSTALLATION  ) 
  19. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY (See  INSTALLATION  ) 
  20. INSTALL FRONT DOOR WINDOW FRAME REAR MOLDING (for 3 Door) (See  INSTALLATION  ) 
  21. INSTALL FRONT DOOR WINDOW FRAME FRONT MOLDING (See  INSTALLATION  ) 
  22. INSTALL FRONT NO.1 SPEAKER ASSEMBLY (See  INSTALLATION  ) 
  23. INSTALL FRONT DOOR GLASS WEATHERSTRIP INNER 
    1. Install the front door glass weatherstrip inner onto the front door trim board.
  24. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 6 claws and install the front door inside handle.
      Fig 23: Identifying Claws Location
      G04834668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the front door lock remote control cable and front door inside locking cable.
      Fig 24: Identifying Front Door Lock Remote Control Cable & Front Door Inside Locking Cable
      G04834667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for 5 Door:

      Engage the 8 clips and install the front door trim board.

      Fig 25: Identifying Clips Location (5 Door)
      G04834738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. for 3 Door:

      Engage the 9 clips and install the front door trim board.

      Fig 26: Identifying Clips Location (3 Door)
      G04834666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the 4 screws.
      Fig 27: Locating Screws
      G04834664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL FRONT ARMREST BASE PANEL UPPER 
    1. Engage the 5 claws and clip and install the front door armrest base panel upper.
      Fig 28: Identifying Claws & Clips Location
      G04834736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL DOOR ARMREST COVER 
    1. for 5 Door:

      Engage the 8 claws and 3 clips and install the door armrest cover.

      Fig 29: Identifying Claws & Clips Location (5 Door)
      G04834734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for 3 Door:

      Engage the 12 claws and 4 clips and install the door armrest cover.

      Fig 30: Identifying Claws & Clips Location (3 Door)
      G04834735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL DOOR WINDOW REGULATOR HANDLE ASSEMBLY 
    1. Install the window regulator handle plate.
    2. Open all the windows.
      Fig 31: Locating Window Regulator Handle Plate
      G04834799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the front door window regulator handle with the clip at the angle shown in Fig 32 .
  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

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

    Fig 32: Identifying Front Door Window Regulator Handle Angle
    G04834800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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