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Home >> Toyota >> 2019 >> Mirai >> Repair and Diagnosis (Single Page) >> Body & Frame >> Exterior Body Panels >> (Doors / Hatch) - Service Information >> Front Door >> Reassembly [06/2015 - 11/2018] >> Procedure

Reassembly [06/2015 - 11/2018]: Procedure

  1. INSTALL FRONT DOOR REAR OUTSIDE STRIPE 

    Refer to PROCEDURE - Step 2

  2. INSTALL FRONT DOOR OUTSIDE STRIPE 

    Refer to PROCEDURE - Step 3

  3. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  4. INSTALL FRONT DOOR WINDOW FRAME REAR MOULDING 

    Refer to PROCEDURE - Step 5

  5. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY 

    Refer to PROCEDURE - Step 1

  6. INSTALL HOLE PLUG 
    1. Install the 3 hole plugs.
      GTY595069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT DOOR PANEL CUSHION 
    1. Engage the claw to install a new front door panel cushion.
      GTY595071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Clean vehicle installation surface.
    2. Engage the clips to install a new front door weatherstrip.
      GTY569327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-side Tape
    3. Install the 2 clips.
    4. Remove the release paper.
    5. Press the double-side tape area of the front door weatherstrip.
  9. INSTALL NO. 2 FRONT DOOR WEATHERSTRIP 
    1. Engage the clips to install the No. 2 front door weatherstrip.
      GTY595207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 3 FRONT DOOR WEATHERSTRIP 
    1. Install the No. 3 front door weatherstrip with the 4 clips.
      GTY595208Courtesy 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. Clean the bolt hole on the vehicle body.
    3. Clean the 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 2 nuts and bolt.
      GTY595209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt 

      Torque: 27 N*m (275 kgf*cm, 20 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 to the front door outside handle frame sub-assembly.
      GTY596795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Snap
    2. Rotate the snap as shown in the illustration to engage the snap to the front door lock open rod.
  13. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY 
    1. Apply MP grease to sliding areas of the front door outside handle frame sub-assembly.
    2. Engage the grommet and guides to install the front door outside handle frame sub-assembly as shown in the illustration.
      GTY566852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Grommet
      *b Guide
      Install in this Direction
    3. Using a T30 "TORX" socket wrench, install the screw.

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

    4. Engage the guide and clamps to install the wire harness.
      GTY595562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clamp
      *b Guide
  14. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the claws to install the front door rear outside handle pad.
      GTY573890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  15. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the claws to install the front door front outside handle pad.
      GTY580827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  16. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY 
    1. Install the front door outside handle assembly as shown in the illustration.
      GTY587855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Connect the connector.
      GTY595066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the claws to close the cover as shown in the illustration.
      GTY593461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  17. INSTALL FRONT DOOR WITH MOTOR LOCK ASSEMBLY 

    Refer to PROCEDURE - Step 4

  18. INSTALL FRONT DOOR OUTSIDE HANDLE COVER RH (for Front Passenger Side) 
    1. Engage the claws to install the front door outside handle cover RH as shown in the illustration.
      GTY540544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Using T30 "TORX" socket wrench, install the screw.

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

    3. Install the hole plug.
      GTY595189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (for Driver Side) 
    1. Engage the guides.
      GTY595084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw to install the front door outside handle cover LH.
  20. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Apply MP grease to the sliding areas of the front door lock cylinder assembly.
    2. Install the front door lock cylinder assembly as shown in the illustration.
      GTY553744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction

      HINT: 

      Check that the front door lock cylinder assembly are attached to the door correctly.

    3. Using a T30 "TORX" socket wrench, install the screw.

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

    4. Install the hole plug.
      GTY610182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP 
    1. Install the front door fix window glass to the front door fix window weatherstrip.
      GTY595196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL FRONT DOOR FIX WINDOW GLASS 
    1. Install the front door fix window glass as shown in the illustration.
      GTY560928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  23. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Install the front door front lower frame sub-assembly with the 3 bolts.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

      GTY595193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Raise up the front door weatherstrip and then install the screw.
    3. Install the front door weatherstrip.
  24. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide to install the front door rear lower frame sub-assembly.
      GTY610184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

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

  25. INSTALL NO. 1 FRONT DOOR STIFFENER CUSHION 
    1. Clean vehicle installation surface.
      GTY566825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Double-side Tape
    2. Remove the release paper.
    3. Install a new No. 1 front door stiffener cushion with the 2 bolts.
    4. Press the double-side tape area of the No. 1 front door stiffener cushion.
  26. INSTALL DOOR FRAME GARNISH 
    1. Engage the guides to install the door frame garnish as shown in the illustration.
      GTY590934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
  27. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run as shown in the illustration.
      GTY544809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  28. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 
    1. Apply MP grease to the sliding areas of the front door window regulator sub-assembly.
    2. Temporarily install the temporary bolt to the front door regulator sub-assembly.
      GTY539403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporary Bolt
    3. Temporarily install the front door window regulator sub-assembly.
    4. Tighten the temporary bolt and 5 bolts to install the front door window regulator sub-assembly.

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

    5. Connect the connector.
  29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. 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.
      GTY551467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
      NOTE:

      Be careful not to damage the front door glass sub-assembly.

    2. Install the front door glass sub-assembly LH with the 2 bolts.

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

  30. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Apply new butyl tape to the front door panel.
      GTY558731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Butyl Tape
      *a Reference Point
    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.
    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.

  31. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  32. INSTALL OUTER MIRROR INSTALL HOLE COVER 

    Refer to PROCEDURE - Step 2

  33. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY 

    Refer to PROCEDURE - Step 1

  34. INSTALL DOOR SIDE AIR BAG SENSOR 

    Refer to PROCEDURE - Step 1

  35. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  36. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP 
    1. Install the front door inner glass weatherstrip as shown in the illustration.
      GTY565458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  37. INSTALL FRONT DOOR WIRE 
    1. Engage the clamps to install the front door wire to the front door trim board sub-assembly.
      GTY595240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side) 

    Refer to PROCEDURE - Step 1

  39. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side) 

    Refer to PROCEDURE - Step 2

  40. INSTALL SEAT MEMORY SWITCH (for Driver Side) 

    Refer to PROCEDURE - Step 1

  41. INSTALL OUTER MIRROR SWITCH ASSEMBLY (for Driver Side) 

    Refer to PROCEDURE - Step 1

  42. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side) 

    Refer to PROCEDURE - Step 1

  43. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the claws to install the front door inside handle sub-assembly to the front door trim board sub-assembly.
      GTY572745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  44. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Engage the guides to connect the front door lock remote control cable assembly and front door inside locking cable assembly.
      GTY595542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
    2. Connect the connector.
      GTY595236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the clamps to install the front door trim board sub-assembly as shown in the illustration.
      GTY579358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    4. Engage the clips as shown in the illustration.
      GTY606499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    5. Install the 3 screws.
      GTY595219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 2

  46. INSTALL NO. 1 FRONT DOOR STIFFENER CUSHION 
    1. Install the No. 1 front door stiffener cushion.
      GTY610190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL FRONT DOOR ARMREST COVER 
    1. Engage the guides and claw to install the front door armrest cover.
      GTY586105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  48. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the claws to install the front door inside handle bezel plug.
      GTY592057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  49. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  50. INSTALL LUGGAGE TRIM SERVICE HOLE COVER 

    Refer to PROCEDURE - Step 3

  51. INITIALIZE POWER WINDOW SYSTEM 

    Refer to INITIALIZATION [06/2015 - ]

  52. INSPECT POWER WINDOW OPERATION 

    Refer to OPERATION CHECK [06/2015 - ]

  53. INSPECT SRS WARNING LIGHT 

    Refer to INITIALIZATION [06/2015 - ]

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