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Reassembly [10/2014 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine 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 [10/2014 - ] ).

  2. REPAIR INSTRUCTION 

    Refer to PROCEDURE - Step 2

  3. INSTALL NO. 2 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 3

  4. INSTALL NO. 1 BLACK OUT TAPE 

    Refer to PROCEDURE - Step 4

  5. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 1

  6. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING 

    Refer to PROCEDURE - Step 2

  7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 2

  8. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP 
    1. Engage the 9 clips to install the front door No. 2 weatherstrip.
      GTY552622Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL DOOR FRAME GARNISH 
    1. Engage the 3 claws to install the door frame garnish.
      GTY600633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 18 clips and install the front door weatherstrip.
      GTY552618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Apply MP grease to the sliding areas of the front door check assembly.
    2. Apply adhesive to the threads of the bolt.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Install the front door check assembly with the 2 nuts and bolt.
      GTY593693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Bolt
      *2 Nut

      Bolt 

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Nut 

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

  12. 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.
      GTY607794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT SMART DOOR WIRE (w/ Smart Key System) 
    1. Engage the 3 clamps to install the front smart door wire.
      GTY552473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.
    2. Engage the claw.
      GTY590084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Outside
      *b Inside
    3. 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) 

    4. w/ Smart Key System:
      1. Engage the 3 clamps.
        GTY552471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Connect the connector.
  15. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY 
    1. Install the front door lock remote control cable assembly.
      GTY376937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY 
    1. Install the front door inside locking cable assembly.
      GTY377199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 6 claws.
      GTY377202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. 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 surface of the connector.
    • Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion. 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.
        GTY552639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insert the front door lock open rod to the front door lock with motor assembly.
      GTY539280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front Door Lock Open Rod
    4. Make sure that the front door lock open rod is securely connected to the front door lock with motor assembly.
    5. 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) 

  18. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 2 claws to install the front door rear outside handle pad.
      GTY552633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the front door front outside handle pad.
      GTY552634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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.
      GTY377178Courtesy 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. Move the lever back in the direction indicated by the arrow in the illustration to lock the front door outside handle assembly.
      GTY377180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. w/ Smart Key System:
      1. Connect the connector.
        GTY377183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Engage the 2 claws.
  21. 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.
      GTY380111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. 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.
      GTY552631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the hole plug.
      GTY600636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. 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.
      GTY552629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the hole plug.
      GTY552630Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide as shown in the illustration.
      GTY552627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front door rear lower frame sub-assembly with the 2 bolts.
  25. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      GTY552760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL NO. 2 FRONT DOOR STIFFENER CUSHION 
    1. Clean the front door panel sub-assembly.
    2. Engage the 2 guides.
      GTY564610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Double-sided Tape
      *2 Guide
    3. Install a new No. 2 front door stiffener cushion with the 2 bolts.
  27. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY 
    NOTE:

    The regulator arm must be below the intermediate position when installing the power window regulator motor.

    1. Using a T25 "TORX" socket wrench, install the front power window regulator motor assembly with the 3 screws.
      GTY552762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

  28. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY 
    1. Apply MP grease to the sliding parts of the front door window regulator assembly.
    2. Install the temporary bolt to the front door window regulator assembly.
    3. Temporarily install the front door window regulator assembly.
      GTY588114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 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) 

  29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. Connect the cable to the negative (-) battery terminal.
    2. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.
    3. 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.

    4. Disconnect the multiplex network master switch assembly.
    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.
      GTY364447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the front door glass sub-assembly with the 2 bolts.
      GTY552757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    7. Install the grommet.
      GTY552755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. 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 and front door inside locking cable assembly through a new front door service hole cover.
      GTY368048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Reference Point
    3. Install the 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 each clamp.
      GTY552752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 connectors.
    6. Install the bolt.
      GTY552746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  31. INSTALL FRONT DOOR TRIM BRACKET 
    1. Install the front door trim bracket with the screw.
      GTY552753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) 

    Refer to PROCEDURE - Step 1

  33. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  34. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  35. INSTALL DOOR SIDE AIRBAG SENSOR 

    Refer to PROCEDURE - Step 1

  36. INSTALL SEAT MEMORY SWITCH (w/ Memory) 

    Refer to PROCEDURE - Step 1

  37. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Engage the 8 claws to install the front door inner glass weatherstrip as shown in the illustration.
      GTY377196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 2 claws and guide, and install the front door inside handle sub-assembly to the front door trim board sub-assembly.
      GTY552620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Connect the front door lock remote control cable assembly and front door inside locking cable assembly.
      TEXT IN ILLUSTRATION

      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
      GTY561713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the 9 clips to install the front door trim board sub-assembly.
      GTY552745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 screws and clip.
      GTY598809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Screw
      *2 Clip

      HINT: 

      If protective tape has been applied, remove it.

  40. INSTALL COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 2

  41. INSTALL NO. 1 FRONT DOOR STIFFENER CUSHION 
    1. Install the No. 1 front door stiffener cushion with the screw.
      GTY552741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side) 
    1. Connect each connector.
    2. w/ illumination:
      1. Engage the 2 clamps.
        GTY600602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the guide and 2 clips.
      GTY377295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 2 guides, clip and 9 claws, and install the multiplex network master switch assembly with front door armrest base panel.
      GTY377297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If protective tape has been applied, remove it.

  43. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side) 
    1. Connect each connector.
    2. w/ illumination:
      1. Engage the 2 clamps.
        GTY552474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the guide and 2 clips.
      GTY377315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 2 guides, clip and 10 claws, and install the power window regulator switch assembly with front door armrest base panel.
      GTY383753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      If protective tape has been applied, remove it.

  44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH 
    1. Engage the clip and claw to install the front door lower frame bracket garnish.
      GTY552742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws to install the front door inside handle bezel plug.
      GTY383818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  47. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    (Refer to INITIALIZATION [10/2014 - ] )

  48. INSPECT POWER WINDOW OPERATION 

    (Refer to OPERATION CHECK [10/2014 - ] )

  49. INSPECT SRS WARNING LIGHT 

    (Refer to DIAGNOSIS SYSTEM [10/2014 - ] )

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