FRONT DOOR (for Sedan): 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.

INSTALL CUSHION
1. Install the 2 cushions onto the door panel.
  
  Fig 1: Locating Cushions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  Fig 2: Locating Front Door Stiffener Cushion Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR WEATHERSTRIP
1. Engage the 35 clips and install the front door weatherstrip.
  
  Fig 3: Identifying Front Door Weatherstrip Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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:
  
  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 4: Identifying Front Door Check Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DOOR OUTSIDE HANDLE PROTECTOR
1. Slide the door outside handle protector to install it.
  
  Fig 5: Sliding Door Outside Handle Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 6: Locating "Torx" Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE PAD FRONT
1. Engage the 2 claws and install the front door outside handle pad front.
  
  Fig 7: Identifying Claws Location (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR
1. Engage the 2 claws and install the front door outside handle pad rear.
  
  Fig 8: Identifying Claws Location (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY
1. Pushing the front door outside handle in the direction of the arrow mark shown in Fig 9, install the front door outside handle.
INSTALL FRONT DOOR LOCK
NOTE:
- If reusing a door lock that has been removed, replace the packing in the connecting part with new.
  
  Fig 9: Pushing Front Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Make sure that no grease or 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.
2. Connect the front door lock remote control cable and front door inside locking cable.
  
  Fig 10: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Close the cover.
  
  Fig 11: Locating Cover
  Courtesy 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 12: Inserting Door Lock Open Rod Into Front Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply adhesive to the threads of the screws.
  Adhesive:
  
  Toyota Genuine Adhesive 1324, 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 13: Locating Front Door Lock Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 14: Identifying Door Lock Key Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER
1. Install the front door frame sub-assembly front lower with the bolt.
  Torque: 6.2 N*m (63 kgf*cm, 54 in.*lbf)
  
  Fig 15: Locating Front Door Frame Sub-Assembly Front Lower Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 16: Locating Front Door Frame Sub-Assembly Rear Lower Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR GLASS RUN
1. Install the front door glass run, then engage the clip.
  
  Fig 17: Locating Front Door Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT (w/ Power Window)
1. Apply MP grease to the sliding and rotating areas of the regulator motor.
2. Using "Torx" socket wrench T25, install the power window regulator motor assembly front with the 3 screws.
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  Fig 18: Locating Power Window Regulator Motor Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
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. w/ Power window:
  1. Loosely screw bolt A onto the front door window regulator.
  2. 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.
  3. Install the front door window regulator with the 5 bolts, and tighten bolt A.
    Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  4. Connect the connector.
    
    Fig 19: Locating Front Door Window Regulator Bolts (1 Of 2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. w/o Power window:
  1. Loosely screw bolt A onto the front door window regulator.
  2. 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.
  3. Install the front door window regulator with the 5 bolts, and tighten bolt A.
    Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  4. Connect the connector.
    
    Fig 20: Locating Front Door Window Regulator Bolts (2 Of 2)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 21: Locating Door Glass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front door glass onto the front door window regulator with the 2 bolts.
  NG: Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
  
  Fig 22: Locating Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT DOOR SERVICE HOLE COVER

Apply butyl tape to the door panel, then install a new front door service hole cover as shown in Fig 23 .

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 23: Applying Butyl Tape To Door Panel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT DOOR TRIM BRACKET
1. Install the front door trim bracket with the 2 screws.
INSTALL FRONT DOOR BELT MOLDING (See INSTALLATION )
INSTALL OUTER REAR VIEW MIRROR (See INSTALLATION )
INSTALL FRONT NO.1 SPEAKER ASSEMBLY (See INSTALLATION )
INSTALL FRONT DOOR GLASS WEATHERSTRIP INNER
1. Install the front door glass weatherstrip inner onto the front door trim board.
  
  Fig 24: Locating Front Door Trim Bracket Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Engage the 4 claws and install the front door inside handle.
  
  Fig 25: Identifying Claws Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY
1. w/ Power window:
  1. Connect the front door lock remote control cable and front door inside locking cable.
    
    Fig 26: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Engage the 9 clips and install the front door trim board.
    
    Fig 27: Identifying Clips Location (With Power Window)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Tighten the screw.
    
    Fig 28: Locating Screw
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. w/o Power window:
  1. Connect the front door lock remote control cable and front door inside locking cable.
    
    Fig 29: Locating Front Door Lock Remote Control Cable & Front Door Inside Locking Cable
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Engage the 9 clips and install the front door trim board.
    
    Fig 30: Identifying Clips Location (Without Power Window)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Tighten the screw.
    
    Fig 31: Locating Screw
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (w/ Power Window)
1. Install the power window regulator master switch with the 3 screws.
  
  Fig 32: Locating Power Window Regulator Master Switch Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/ Power Window)
1. Engage the 2 claws and install the power window regulator switch.
  
  Fig 33: Identifying Claws Location (With Power Window)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DOOR CONTROL SWITCH (w/ Power Door Lock)
1. Engage the 2 claws and install the door control switch.
  
  Fig 34: Identifying Claws Location (With Power Door Lock)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT ARMREST BASE UPPER PANEL
1. for Driver side with power window:
  1. Connect the connector.
  2. Engage the 7 claws and 2 clips and install the front armrest base upper panel.
  3. Tighten the screw.
    
    Fig 35: Identifying Claws & Clips Location (Driver Side With Power Window)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. for Front passenger side with power window:
  1. Connect the connector.
  2. Engage the 7 claws and 2 clips and install the front armrest base upper panel.
  3. Tighten the screw.
    
    Fig 36: Identifying Claws & Clips Location (Front Passenger Side With Power Window)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. w/o Power window:
  1. Engage the 5 clips and 2 clips and install the front armrest base upper panel.
  2. Tighten the screw.
    
    Fig 37: Identifying Claws & Clips Location (Without Power Window)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
1. Engage the claw and clip and install the front door lower frame bracket garnish.
  
  Fig 38: Identifying Claw & Clip Location
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)
1. Install the window regulator handle plate.
2. Open all the windows.
  
  Fig 39: Locating Window Regulator Handle Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the front door window regulator handle with the clip at the angle shown in Fig 40 .
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

Fig 40: Identifying Front Door Window Regulator Handle Angle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002