Reassembly [08/2015 - ]

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PRECAUTION
NOTE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work. Refer to PRECAUTION [08/2015 - ] .
REPAIR INSTRUCTION . Refer to INSTALLATION [08/2015 - ] - Step 2
INSTALL FRONT DOOR LOWER OUTSIDE STRIPE . Refer to INSTALLATION [08/2015 - ] - Step 3
INSTALL FRONT DOOR STRIPE . Refer to INSTALLATION [08/2015 - ] - Step 4
INSTALL FRONT DOOR UPPER WINDOW FRAME MOLDING . Refer to INSTALLATION [08/2015 - ] - Step 2
INSTALL FRONT DOOR REAR WINDOW FRAME MOLDING . Refer to INSTALLATION [08/2015 - ] - Step 3
INSTALL FRONT DOOR BELT MOLDING ASSEMBLY . Refer to INSTALLATION [08/2015 - ] - Step 2
INSTALL FRONT DOOR PANEL PROTECTOR
1. Install the front door panel protector.
  
  Fig 1: Front Door Panel Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR PANEL CUSHION
1. Engage the 2 claws to install 2 new front door panel cushions.
  
  Fig 2: Identifying Front Door Panel Cushions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR NO. 2 WEATHERSTRIP
1. Engage the 8 clips to install the front door No. 2 weatherstrip.
  
  Fig 3: Identifying Front Door No. 2 Weatherstrip Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DOOR FRAME GARNISH
1. Engage the clip to install a new door frame garnish.
  
  Fig 4: Identifying Door Frame Garnish Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR WEATHERSTRIP
1. Engage the 19 clips and install the front door weatherstrip.
  
  Fig 5: Identifying Front Door Weatherstrip Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR CHECK ASSEMBLY
1. Apply MP grease to the sliding parts of the front door check assembly.
2. Clean the bolt hole on the vehicle body.
3. Clean the bolt threads of the bolt.
4. Apply adhesive to the threads of the bolt.
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
5. Install the front door check assembly with the 3 bolts.
  
  Fig 6: Identifying Front Door Check Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt (A)
  
  Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
  
  Bolt (B)
  
  Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
INSTALL FRONT DOOR LOCK OPEN ROD
1. Install the front door lock open rod as indicated by the arrows, in the order shown in the illustration.
  
  Fig 7: Identifying Front Door Lock Open Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR WIRE (w/ Smart Key System)
1. Engage the 3 clamps to install the front door wire.
  
  Fig 8: Identifying Front Door Wire Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.

Engage the claw.

Fig 9: Identifying Screw And Door Handle Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Door Handle Nut
*a	Outside
*b	Inside

Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw and door handle nut.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
w/ Smart Key System:
1. Engage the 3 clamps.
  
  Fig 10: Identifying Connector And Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the connector.

INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY
1. Install the front door inside locking cable assembly.
  
  Fig 11: Installing Front Door Inside Locking Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engage the 3 claws.
  
  Fig 12: Identifying Front Door Inside Locking Cable Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
1. Install the front door lock remote control cable assembly.
  
  Fig 13: Installing Front Door Lock Remote Control Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY
NOTE:
- When reusing the removed front door lock with motor assembly, replace the door lock wiring harness seal on the connector with a new one.
- Do not allow grease or dust to adhere to the door lock wiring harness seal installation surface.
- Reusing a door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water ingress. This may result in a malfunction of the front door lock with motor assembly.
1. Apply MP grease to the sliding parts of the front door lock with motor assembly.
2. When reusing the front door lock with motor assembly:
  1. Install a new door lock wiring harness seal to the front door lock with motor assembly.
    
    Fig 14: Identifying Door Lock Wiring Harness Seal
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the front door lock open rod to the front door lock with motor assembly.
  
  Fig 15: Locating Front Door Lock Open Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Front Door Lock Open Rod
  
  HINT:
  
  Make sure that the front door lock open rod is securely connected to the front door lock with motor assembly.
4. Using a T30 "TORX" socket wrench, install the front door lock with motor assembly with the 3 screws.
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
1. Engage the 2 claws to install the front door rear outside handle pad.
  
  Fig 16: Identifying Front Door Rear Outside Handle Pad Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
1. Engage the 3 claws to install the front door front outside handle pad.
  
  Fig 17: Identifying Front Door Front Outside Handle Pad Claws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY
1. Insert the front end of the front door outside handle assembly into the front door outside handle frame.
  
  Fig 18: Installing Front Door Outside Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame, then slide the front door outside handle assembly toward the front of the vehicle to install it.
3. w/ Smart Key System:
  1. Connect the connector.
    
    Fig 19: Identifying Front Door Outside Handle Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Engage the 2 claws.
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)
1. Engage the 2 guides and claw, and install the front door outside handle cover to the lock cylinder assembly as shown in the illustration.
  
  Fig 20: Removing Front Door Outside Handle Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
1. Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.
  
  Fig 21: Removing/Installing Front Door Outside Handle Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Install the hole plug.
  
  Fig 22: Identifying Front Door Hole Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)
1. Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw.
  
  Fig 23: Removing/Installing Front Door Outside Handle Cover With Lock Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)
2. Install the hole plug.
  
  Fig 24: Identifying Front Door Hole Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY
1. Engage the guide as shown in the illustration.
  
  Fig 25: Identifying Front Door Rear Lower Frame Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front door rear lower frame sub-assembly with the 2 bolts.
INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY
1. Engage the guide as shown in the illustration.
  
  Fig 26: Identifying Front Door Front Lower Frame Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front door front lower frame sub-assembly with the 2 bolts.
INSTALL FRONT DOOR GLASS RUN
1. Install the front door glass run.
  
  Fig 27: Identifying Front Door Glass Run
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION
1. Clean the front door panel.
2. Engage the 2 guides.
  
  Fig 28: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Double-sided Tape
3. Install a new No. 2 front door stiffener cushion with the 2 bolts.
INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY
NOTE:
The regulator arm must be below the intermediate position when installing the front power window regulator motor.
1. Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws.
  
  Fig 29: Identifying Screws And Front Power Window Regulator Motor Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
  
  HINT:
  
  When replacing a front power window regulator motor assembly, a new front power window regulator motor assembly uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.
INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY
1. Apply MP grease to the sliding parts of the front door window regulator assembly.
2. Temporarily install the temporary bolt to the front door window regulator assembly.
3. Temporarily install the front door window regulator assembly with the 5 bolts.
  
  Fig 30: Identifying Front Door Window Regulator Assembly With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Temporary Bolt
4. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly.
  HINT:
  
  Tighten the bolts in the order shown in the illustration.
  
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
1. Connect the cable to the negative (-) battery terminal.
2. for Driver Side:
  1. Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
  2. Disconnect the power window regulator master switch assembly.
3. for Front Passenger Side:
  1. Connect the power window regulator switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
  2. Disconnect the power window regulator switch assembly.
4. Disconnect the cable from the negative (-) battery terminal.
  WARNING:
  Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
  
  NOTE:
  When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION [08/2015 - ] .
5. Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated by the arrows, in the order shown in the illustration.
  
  Fig 31: Inserting Front Door Glass Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not damage the front door glass sub-assembly.
6. Install the front door glass sub-assembly with the 2 bolts.
  
  Fig 32: Identifying Front Door Glass Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
7. Install the grommet.
  
  Fig 33: Identifying Front Door Grommet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 FRONT DOOR SERVICE HOLE SEAL
1. Install the No. 2 front door service hole seal.
  
  Fig 34: Locating No. 2 Front Door Service Hole Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 FRONT DOOR SERVICE HOLE SEAL
1. Install the No. 1 front door service hole seal.
  
  Fig 35: Locating No. 1 Front Door Service Hole Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR SERVICE HOLE COVER
1. Apply new butyl tape to the front door panel.
2. Pass the front door lock remote control cable assembly, front door inside locking cable assembly and each connector through a new front door service hole cover.
  
  Fig 36: Identifying Reference Points
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *a Reference Point
3. Install the new front door service hole cover according to the reference points on the front door panel.
  NOTE:
  Securely install the front door service hole cover preventing wrinkles and air bubbles.
4. Engage the 5 clamps.
5. Install the bolt.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
6. Connect each connector.
INSTALL OUTER REAR VIEW MIRROR ASSEMBLY . Refer to INSTALLATION [08/2015 - ] - Step 1
INSTALL FRONT NO. 1 SPEAKER ASSEMBLY . Refer to INSTALLATION [08/2015 - ] - Step 1
INSTALL DOOR SIDE AIRBAG SENSOR . Refer to INSTALLATION [08/2015 - ] - Step 1
INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
1. Engage the 3 clips to install the front door lower frame bracket garnish.
  
  Fig 37: Identifying Clips And Front Door Lower Frame Bracket Garnish
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP
1. Install the front door inner glass weatherstrip.
  
  Fig 38: Locating Front Door Inner Glass Weatherstrip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
1. Engage the 2 claws and guide to install the front door inside handle sub-assembly to the front door trim board sub-assembly.
  
  Fig 39: Locating Claws And Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

Connect the front door lock remote control cable assembly and front door inside locking cable assembly.

Fig 40: Identifying Front Door Inside Locking Cable Assembly And Front Door Lock Remote Control Cable Assembly

TEXT IN ILLUSTRATION

*1	Front Door Inside Locking Cable Assembly
*2	Front Door Lock Remote Control Cable Assembly

Engage the clamp.
Engage the 4 claws and reference boss as shown in the illustration.

Fig 41: Identifying Claws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION

*a Reference Boss
Engage the 10 clips to install the front door trim board sub-assembly.

Fig 42: Identifying Clips And Front Door Trim Board Sub-Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the 3 screws.
Remove protective tape.

INSTALL COURTESY LIGHT ASSEMBLY . Refer to INSTALLATION [08/2015 - ] - Step 1
INSTALL FRONT ARMREST ASSEMBLY
1. Engage the 2 guides, 3 clips and 7 claws to install the front armrest assembly.
  
  Fig 43: Identifying Front Armrest Assembly Clips, Claws And Guides
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)
1. Connect each connector.
2. Engage the 3 guides, 2 clips and 6 claws to install the power window regulator master switch assembly with front door armrest base panel.
  
  Fig 44: Locating Guides, Clips And Claws (Driver Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)
1. Connect each connector.
2. Engage the 3 guides, 2 clips and 6 claws to install the power window regulator switch assembly with front door armrest base panel.
  
  Fig 45: Locating Guides, Clips And Claws (Passenger Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER
1. Engage the 2 guides and 2 claws to install the front door front lower frame upper cover.
  
  Fig 46: Locating Claws And Guides
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG
1. Engage the 3 claws to install the front door inside handle bezel plug.
  
  Fig 47: Locating Claws And Front Door Inside Handle Bezel Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION [08/2015 - ] .
INITIALIZE POWER WINDOW CONTROL SYSTEM
Refer to INITIALIZATION [08/2015 - ]
INSPECT POWER WINDOW OPERATION
Refer to OPERATION CHECK [08/2015 - ]
INSPECT SRS WARNING LIGHT
Refer to DIAGNOSIS SYSTEM [08/2015 - ]