LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2021 >> Prius Prime LE >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> (Door / Hatch) (Service Information) (1 Of 2) >> Front Door >> Reassembly [09/2016 - ] >> Procedure

Reassembly [09/2016 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Refer to PRECAUTION [09/2016 - 01/2018] , or refer to PRECAUTION [01/2018 - 05/2019] , or refer to PRECAUTION [05/2019 - ]

  2. INSTALL FRONT DOOR FRONT WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 1

  3. INSTALL COWL SIDE TRIM BOARD 

    Refer to PROCEDURE - Step 47 [09/2016 - 05/2019] , or refer to PROCEDURE - Step 43 [05/2019 - 07/2020] , or refer to PROCEDURE - Step 45 [07/2020 - ]

  4. INSTALL FRONT DOOR SCUFF PLATE 

    Refer to PROCEDURE - Step 48 [09/2016 - 05/2019] , or refer to PROCEDURE - Step 44 [05/2019 - 07/2020] , or refer to PROCEDURE - Step 46 [07/2020 - ]

  5. REPAIR INSTRUCTION (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 1

  6. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 2

  7. INSTALL FRONT DOOR STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 3

  8. INSTALL FRONT DOOR REAR OUTSIDE STRIPE (w/ Black Out Tape) 

    Refer to PROCEDURE - Step 4

  9. INSTALL FRONT DOOR UPPER WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 4

  10. INSTALL FRONT DOOR REAR WINDOW FRAME MOLDING 

    Refer to PROCEDURE - Step 9

  11. INSTALL FRONT DOOR BELT MOLDING ASSEMBLY 

    Refer to PROCEDURE - Step 1

  12. INSTALL FRONT DOOR DUST PROOF SEAL 
    1. Engage the 3 claws to install 3 new front door dust proof seals.
      GTY609600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL FRONT DOOR PANEL CUSHION 
    1. Engage the 4 claws to install 2 new front door panel cushions.
      GTY592603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DOOR FIX WINDOW GLASS 
    1. Install the front door fix window glass to the front door fix window weatherstrip.
    2. Install the front door fix window glass with the front door fix window weatherstrip as shown in the illustration.
      GTY584520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  15. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY 
    1. Install the front door front lower frame sub-assembly with the 3 bolts and screw.
      GTY599209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw

      Bolt 

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

      Screw 

      Torque: 3.1 N*m (32 kgf*cm, 27 in.*lbf) 

  16. INSTALL DOOR FRAME GARNISH 
    1. Engage the 3 claws to install the door frame garnish.
      GTY592966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT DOOR WEATHERSTRIP 
    1. Engage the 21 clips and install the front door weatherstrip.
      GTY589760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL FRONT DOOR CHECK ASSEMBLY 
    1. Apply MP grease to the sliding parts of the front door check assembly.
    2. Clean the bolt hole in the vehicle body.
    3. Clean the threads of the bolt (B).
    4. Apply adhesive to the threads of the bolt (B).

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the front door check assembly with the 3 bolts.
      GTY543110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

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

      Bolt (B) 

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

  19. 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.
      GTY587895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
  20. 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 as shown in the illustration.
      GTY578181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Outside
      *B Inside
    3. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.

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

  21. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  22. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD 
    1. Engage the 3 guides.
      GTY592624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the claw to install the front door rear outside handle pad.
  23. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD 
    1. Engage the 3 claws to install the front door front outside handle pad.
      GTY592625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side) 
    1. Engage the 2 guides and claw.
      GTY592634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

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

    3. Install the hole plug.
      GTY553082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side) 
    1. Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly with the screw.
      GTY592635Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the hole plug.
      GTY553081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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 sub-assembly.
      GTY569179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame sub-assembly, then slide the front door outside handle assembly toward the front of the vehicle to install it.
    3. Move the lever as shown in the illustration and engage the 2 claws to secure the front door outside handle assembly.
      GTY553004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Engage in this Direction
    4. Engage the 3 clamps.
      GTY609605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the connector.
      GTY592640Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Engage the 2 claws.
  27. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY 
    1. Engage the guide as shown in the illustration.
      GTY595281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Install the front door rear lower frame sub-assembly with the bolt.

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

  28. INSTALL FRONT DOOR GLASS RUN 
    1. Install the front door glass run.
      GTY592942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. 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 1: Front Door Window Regulator Assembly Tightening Sequence
      GTY550502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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) 

    5. Connect the connector.
    6. Engage the 2 claws to install the front door No. 2 service hole cover.
      GTY592947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY 
    1. for Driver Side:
      1. Connect the multiplex network master switch assembly.
    2. for Front Passenger Side:
      1. Connect the power window regulator switch assembly.
    3. Connect the cable to the negative (-) auxiliary battery terminal.
    4. Turn the power switch on (IG).
    5. Move the front door window regulator assembly so that the door glass bolt holes can be seen.
    6. Turn the power switch off.
    7. Disconnect the cable from the negative (-) auxiliary battery terminal.
    8. for Driver Side:
      1. Disconnect the multiplex network master switch assembly.
    9. for Front Passenger Side:
      1. Disconnect the power window regulator switch assembly.
    10. Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.
      GTY563091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction (1)
      Install in this Direction (2)
    11. Install the front door glass sub-assembly with the 2 bolts.
      GTY609679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    12. Install the hole plug.
      GTY592952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL DOOR SIDE AIRBAG SENSOR 

    Refer to PROCEDURE - Step 1

  32. INSTALL FRONT DOOR SERVICE HOLE COVER 
    1. Engage the 4 clips to install the front door service hole cover.
      GTY592954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert 3 front door weatherstrip clips and turn them 45 degrees as shown in the illustration to install them.
      GTY592957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  34. INSTALL FRONT DOOR NO. 3 SERVICE HOLE COVER 
    1. Install the front door No. 3 service hole cover.
      GTY592602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  36. INSTALL FRONT DOOR PANEL PROTECTOR 

    Refer to PROCEDURE - Step 2

  37. INSTALL FRONT DOOR VENT SEAL 
    1. Install the front door vent seal to the front door inner glass weatherstrip.
      GTY602367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  38. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP 
    1. Install the front door inner glass weatherstrip with front door vent seal as shown in the illustration.
      GTY605617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  39. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 
    1. Engage the 2 claws to install the front door inside handle sub-assembly.
      GTY592967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY 
    1. Engage the clip.
      GTY720047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the front door lock remote control cable assembly and front door inside locking cable assembly to the front door inside handle sub-assembly as shown in the illustration.
      GTY545931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Door Inside Locking Cable Assembly
      *2 Front Door Lock Remote Control Cable Assembly
      Install in this Direction
    3. Engage the guide and 6 claws.
      GTY1006810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the 10 clips to install the front door trim board sub-assembly.
    5. Install the 3 screws.
      GTY592977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL COURTESY LIGHT ASSEMBLY 

    Refer to PROCEDURE - Step 2

  42. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Driver Side) 
    1. Connect the connector.
    2. Engage the 2 clips and 4 claws to install the multiplex network master switch assembly with front door upper armrest base panel as shown in the illustration.
      GTY577734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  43. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR UPPER ARMREST BASE PANEL (for Front Passenger Side) 
    1. Connect the connector.
    2. Engage the 2 clips and 4 claws to install the power window regulator switch assembly with front door upper armrest base panel as shown in the illustration.
      GTY549603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  44. INSTALL FRONT ARMREST ASSEMBLY 
    1. Engage the guide as shown in the illustration.
      GTY541561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
    2. Engage the 3 clips and 7 claws to install the front armrest assembly as shown in the illustration.
      GTY594489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction
  45. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG 
    1. Engage the 3 claws to install the front door inside handle bezel plug.
      GTY570152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [09/2016 - 05/2019] , or refer to INITIALIZATION [05/2019 - 07/2020] , or refer to INITIALIZATION [07/2020 - ]

  47. INITIALIZE POWER WINDOW CONTROL SYSTEM 

    Refer to INITIALIZATION [09/2016 - ]

  48. INSPECT POWER WINDOW OPERATION 

    Refer to OPERATION CHECK [09/2016 - 12/2018] , or refer to OPERATION CHECK [12/2018 - ]

  49. INSPECT SRS WARNING LIGHT 

    Refer to DIAGNOSIS SYSTEM [09/2016 - 05/2019] , or refer to OPERATION CHECK [05/2019 - 07/2020] , or refer to OPERATION CHECK [07/2020 - ]

scientia non olet · About LEMON Manuals