FRONT DOOR > REASSEMBLY

for Preparation Click here

HINT:

1. Use the same procedure for both the RH and LH sides.
   
2. The procedure described below is for the RH side.
   

1. Install the 2 cushions onto the door panel.
   

1. Engage the 25 clips and install the front door weatherstrip.
   

1. Engage the clamp and install the electrical key wire harness as shown in the illustration.
   

1. Apply MP grease to the sliding areas of the front door outside handle frame.
   

2. Slide the front door outside handle frame to install it.
   

3. 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 }

1. Apply MP grease to the sliding areas of the front door outside handle frame.
   

2. Slide the front door outside handle frame to install it.
   

3. 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 }

4. Connect the connector.
   

5. Engage the 4 clamps.
   

1. Engage the 2 claws and install the front door outside handle rear pad.
   

1. Engage the 3 claws and install the front door outside handle front pad.
   

1. Pushing the front door outside handle in the direction of the arrow mark shown in the illustration, install the front door outside handle.
   

2. Pull down the door handle holder as shown by the arrow and lock the front door outside handle.
   

1. Pushing the front door outside handle in the direction of the arrow mark shown in the illustration, install the front door outside handle.
   

2. Pull down the door handle holder as shown by the arrow and lock the front door outside handle.
   

3. Connect the connector.
   

4. Engage the 4 claws and install the connector cover.
   

5. Engage the clamp.
   

1. Apply MP grease to the sliding and rotating areas of the front door lock.
   

2. Install a new door lock wire harness seal.
   

   NOTICE:

   1. If reusing the door lock replace the wire harness seal with new seal.
      
   2. Make sure that no grease and dirt adheres to the wire harness seal surface.
      

3. Insert the front door lock open rod into the front door lock, and set it to the front door outside handle frame.
   

4. Make sure that the front door lock open rod is securely connected to the front door lock.
   

5. Apply adhesive to the threads of the screws.
   

   Adhesive:

   Toyota Genuine Adhesive 1324, Three Bond 1324 or 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 }

1. Engage the 2 claws and install the lock cylinder.
   

2. Using "TORX" socket wrench T30, install the cover.
   

   Torque:

   4.0 N*m{ 41 kgf*cm , 35 in.*lbf }

3. Install the hole plug.
   

1. Using "TORX" socket wrench T30, install the cover.
   

   Torque:

   4.0 N*m{ 41 kgf*cm , 35 in.*lbf }

2. Install the hole plug.
   

1. Install the front door frame rear lower sub-assembly with the bolt.
   

   Torque:

   6.2 N*m{ 63 kgf*cm , 55 in.*lbf }

1. Apply MP grease to the sliding areas of the front 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 equivalent
   

4. Install the front door check onto the body panel with the bolt.
   

   Torque:

   30 N*m{ 306 kgf*cm , 22 ft.*lbf }

1. Install a new front door stiffener cushion with the 2 bolts and apply thorough pressure to the sections with double-sided tape.
   

   Text in Illustration 

   *1	Double-sided Tape

   Torque:

   8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

1. Install the nut (C), engage the clamp, and install the front door window regulator.
   

   Torque:

   8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

2. Install the 3 nuts (B) and engage the 3 clamps.
   

   Torque:

   8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

3. Install the 3 bolts.
   

   Torque:

   8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

4. Engage the clamp (A).
   

5. Install the regulator wire to the holder.
   

6. Connect the connector.
   

1. Install the front door glass run.
   

1. Insert the front door glass into the door panel along the glass run as indicated by the arrows in the illustration.
   

   NOTICE:

   Do not damage the front door glass.

2. Install the front door glass onto the front door window regulator with the 2 bolts.
   

   Torque:

   8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

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

   HINT:

   1. When installing the service hole cover, pull the links and connectors out through the service hole.
      
   2. There should be no wrinkles or folds after attaching the service hole cover.
      
   3. After attaching the service hole cover, check the quality of the seal.
      

2. Engage the clamps.
   

3. Install the ground wire with the bolt.
   

4. Connect the connector.
   

1. Confirm that the ignition switch off.
   

2. Confirm that the cable is disconnected from the battery negative (-) terminal.
   

   CAUTION:

   Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.

3. Engage the guide and install the airbag sensor with the bolt.
   

   Torque:

   9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

   NOTICE:

   1. Do not use a side airbag sensor that has been dropped.
      
   2. Do not subject the side airbag sensor to any impact or force.
      

4. Confirm that there is no looseness by shaking the side airbag sensor.
   

5. Connect the airbag connector.
   

   Text in Illustration 

   *1	Outer Housing

HINT:

Use the same procedure as for the LH side (Click here).

HINT:

Use the same procedure as for the LH side (Click here).

HINT:

Use the same procedure as for the LH side (Click here).

1. Using an air riveter or hand riveter, install the front No. 1 speaker with 3 new strike rivets.
   

   HINT:

   Install the new strike rivets in the order shown in the illustration.

   
   

   NOTICE:

   1. Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
      
   
   
   2. Confirm that the rivets are seated properly against the speaker.
      
   3. Do not tilt the riveter when installing the rivet into the speaker.
      
   4. Do not leave any space between the rivet head and speaker.
      
   
   
   5. Do not leave any space between the speaker and door. Firmly hold together the 2 items while installing the rivet.
      

2. Connect the connector.
   

1. Install the front door glass inner weatherstrip.
   

1. Engage the 3 claws and install the front No. 2 speaker.
   

1. Engage the 2 claws and install the front door inside handle.
   

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

2. Engage the 6 claws and 10 clips and install the front door trim board.
   

3. Tighten the 3 screws.
   

4. Connect the connector.
   

1. Engage the 4 claws and install the door speaker grille base.
   

1. Engage the 6 claws and install the door assist grip cover.
   

1. Engage the 4 claws and install the front door inside handle bezel.
   

1. Connect the connector.
   

2. Engage the 6 claws and install the front armrest base upper panel.
   

1. Engage the claw and install the door armrest cap.
   

2. Connect the connector.
   

3. Engage the 6 claws and install the front armrest base upper panel.
   

4. Install the screw.
   

5. Engage the claw and close the door armrest cap.
   

1. Engage the 2 guides and the clip and install the front door lower frame bracket garnish.
   

Torque:

5.4 N*m{ 55 kgf*cm , 49 in.*lbf }