Front Door Reassembly

Attach the clip to install a new door panel cushion.

Clean the vehicle body surface.

1. Using a heat light, heat the vehicle body surface.
   

2. Wipe off any tape adhesive residue with cleaner.
   

Installation temperature.

1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is higher than 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape to between 20 and 30°C (68 and 86°F) prior to installation.
   

   HINT:

   1. The most appropriate temperature for installing the tape is 25°C (77°F).
      
   2. When the temperature is low, the tape turns stiff and falls off easily. When the temperature is high, the tape loses elasticity.
      

Before installation.

1. Make sure any dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame) is removed, and that the surface is smooth. If the surface is rough or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.
   

   HINT:

   Spray water on the shop floor to settle any dust.

Key points for handling the tape.

1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and level.
   

   NOTICE:

   Do not bend the tape or leave it in a place with a high temperature.

Key points for the installation of the tape (how to use a squeegee and the installation procedure for a flat surface).

NOTICE:

1. Position the tape with a high level of accuracy to achieve a neat finish and to avoid peeling.
   
2. The tape cannot be reused because it deforms and will not fit after removal.
   

1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee 40 to 50° (for pressing forward) or 30 to 45° (for pulling) from the vehicle body surface and press with a force of 20 to 30 N (2 to 3 kgf) while moving the squeegee at a constant slow speed of 3 to 7 cm (1.2 to 2.8 in.) per second.
   
   

   
   
   
   

   NOTICE:

   Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles and air bubbles.

   HINT:

   1. Either angle of the squeegee (for pressing forward or for pulling) is acceptable.
      
   2. Be sure to apply the tape while removing the release paper 10 to 20 mm (0.393 to 0.787 in.) from the edge of the squeegee.
      
   
   

   Text in Illustration

   *A	Pressing	*B	Pulling
   *1	Squeegee	*2	Black Out Tape
   *3	Release Paper	-	-
   *a	Sectional View	*b	Non-padded Side
   *c	Padded Side	-	-

Key points for the installation of the tape (how to use a squeegee and the installation procedure for hemming surfaces).

1. If it is difficult to press the tape, press it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.
   

   HINT:

   When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

   Text in Illustration

   *1	Squeegee
   *a	First
   *b	Second
   *c	Third

Key points for the installation of the tape (how to use a squeegee and the installation procedure for corners).

1. Remove the release paper and apply the tape carefully with your fingers.
   

2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it to avoid wrinkles in the tape and achieve a neat finish.
   

Check after installation.

1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, apply new tape.
   

   NOTICE:

   Do not reuse the tape.

Refer to the illustration to position a new lower front door outside stripe.

Reference Value:

Area	Specified Condition
A	+/-1.0 mm (0.039 in.) from End

Refer to the illustration to position a new front door outside stripe.

Reference Value:

Area	Specified Condition
A	+/-1.0 mm (0.039 in.) from End

Refer to the illustration to position a new black out tape.

Reference Value:

Area	Specified Condition
A	2 to 4 mm (0.078 to 0.158 in.)
B	4 to 6 mm (0.157 to 0.236 in.)

Clean the vehicle body surface.

1. Using a heat light, heat the vehicle body surface.
   

2. Remove the double-sided tape from the vehicle body surface.
   

3. Wipe off any tape adhesive residue with cleaner.
   

Install a new front door rear window frame moulding.

1. Using a heat light, heat a new front door rear window frame moulding and the vehicle body surface.
   

2. Remove the peeling paper from the face of the front door rear window frame moulding.
   

   HINT:

   After removing the peeling paper, keep the exposed adhesive free from foreign matter.

3. Attach the clip and double-sided tape to install the front door rear window frame moulding.
   

   HINT:

   Press the front door rear window frame moulding firmly to install it.

Install a new door window frame moulding clip.

Attach the 6 claws to install the front door belt moulding.

Attach the 21 clips to install a new front door weatherstrip.

Apply MP grease to the sliding areas of the front door check assembly.

Install the door check to the door panel with the 2 nuts.

Torque:

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

Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the front door check assembly with the bolt.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

Clean the installation surface.

1. Using a heat light, heat the installation surface.
   

   Standard:

   Item	Temperature
   Vehicle body	40 to 60°C (104 to 140°F)

   NOTICE:

   Do not heat the vehicle body excessively.

2. Remove the double-sided tape from the installation surface.
   

3. Wipe off any tape adhesive residue with cleaner.
   

Install a new door stiffener cushion.

1. Using a heat light, heat a new front door No. 2 stiffener cushion and the installation surface.
   

   HINT:

   When installing the front door No. 2 stiffener cushion, heat the vehicle body and door stiffener cushion using a heat light.

   Standard:

   Item	Temperature
   Door stiffener cushion	20 to 30°C (68 to 86°F)
   Vehicle body	40 to 60°C (104 to 140°F)

   NOTICE:

   Do not heat the door stiffener cushion and vehicle body excessively.

2. Remove the peeling paper from the face of the door stiffener cushion.
   

   HINT:

   After removing the peeling paper, keep the exposed adhesive free from foreign matter.

3. Attach the 2 clamps and double-sided tape to install the front door No. 2 stiffener cushion.
   

   HINT:

   Press the front door No. 2 stiffener cushion firmly to install it.

4. Install the 2 bolts.
   

Install the front door lock open rod as indicated by the arrows in the order shown in the illustration.

Attach the 4 clamps to install the front door No. 2 wire.

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

Attach the door handle nut and claw.

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}

w/ Entry and Start System:

1. Attach the clamp.
   

2. Connect the front door No. 2 wire connector to the front door wire.
   

Attach the 2 claws to install the front door rear outside handle pad.

Attach the 3 claws to install the front door front outside handle pad.

Insert the front end of the front door outside handle assembly into the front door outside handle frame.

Insert the rear end of the front door outside handle assembly into the front door outside handle frame, and then slide the front door outside handle assembly toward the front of the vehicle to install it.

Move the lever in the direction indicated by the arrow in the illustration to lock the door outside handle assembly.

Connect the connector.

Attach the 2 claws.

Install the front door inside locking cable assembly.

Attach the 3 claws.

Install the front door lock remote control cable assembly.

Apply MP grease to the sliding parts of the front door lock assembly.

Install a new door lock wiring harness seal to the front door lock assembly.

Insert the front door lock open rod to the front door lock assembly.

Text in Illustration

*A	w/o Double Locking System
*B	w/ Double Locking System
	Slide

Check that the front door lock open rod is securely connected to the front door lock assembly.

Using a T30 "TORX" wrench, install the front door lock assembly with the 3 screws.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the connector.

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}

Install the hole plug.

Attach the claw to install the front door outside handle cover to the front door lock cylinder.

Install the front door outside handle cover with lock cylinder assembly.

HINT:

Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

Using a T30 "TORX" socket wrench, install the front door lock cylinder with the screw.

Torque:

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

Install the hole plug.

Install the front door rear lower frame sub-assembly with the bolt as shown in the illustration.

Install the front door glass run.

Attach the clip to install a new door frame garnish.

Apply MP grease to the sliding and rotating areas of the regulator motor.

Using a T25 "TORX" socket wrench, install the power window regulator motor with the 3 screws.

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.

Apply MP grease to the sliding parts of the front door window regulator assembly.

Install the temporary bolt to the front door window regulator assembly.

Temporarily install the front door window regulator assembly with the temporary bolt.

Temporarily install the 5 bolts, and then tighten the temporary bolt and 5 bolts.

Torque:

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

HINT:

Tighten the bolts in the order shown in the illustration.

Connect the connector.

Connect the cable to the negative (-) battery terminal.

Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolt installation locations can be seen.

Disconnect the cable from the negative (-) battery terminal and power window regulator master switch assembly.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system (LandCruiser RM000003YMF011X.html).

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.

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

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}

HINT:

Tighten the bolts in the order shown in the illustration.

Attach the claw to install the outer rear view mirror, and then install the 3 nuts.

Torque:

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

Connect the connector.

Apply new butyl tape to the front door panel.

Pass the front door lock remote control cable assembly and front door inside locking cable assembly through a new front door service hole cover.

Attach the front door service hole cover using the reference points on the front door panel.

NOTICE:

1. There should be no wrinkles or folds after attaching the service hole cover.
   
2. After attaching the service hole cover, check the seal quality.
   

NOTICE:

Securely install the front door service hole cover preventing wrinkles and air bubbles.

Attach the 2 clamps.

Install the bolt to the front door wire.

Check that the ignition switch is off.

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

CAUTION:

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

Install the side airbag sensor with the bolt.

Torque:

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

NOTICE:

1. If the side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
   
2. When installing the side airbag sensor, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts.
   

Check that the side airbag sensor is not loose.

Connect the connector.

Temporarily install the speaker by attaching the 2 claws of the speaker to the door panel.

Install the speaker with the 4 screws in the order shown in the illustration.

Connect the speaker connector.

NOTICE:

Do not touch the cone of the speaker.

Install the switch with the 2 screws.

Attach the guide and 2 claws to install the front door inside handle sub-assembly to the front door trim board sub-assembly.

Install the 2 screws.

Install the 8 screws to the door assist grip assembly LH.

Attach the 2 claws to install the power window regulator switch assembly.

Install the multiplex network master switch assembly with the 3 screws.

Attach the claw to install the light.

Connect the connector.

Turn the light in the direction indicated by the arrow to install it.

Attach the clamp.

Connect the connector.

Attach the 2 claws to install the front reflex reflector assembly.

Install the front door inner glass weatherstrip.

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

Connect 2 connectors.

w/ Seat Position Memory System:

1. Connect the connectors.
   

Attach the front door trim board sub-assembly by attaching the 4 claws of the front door inner glass weatherstrip as shown in the illustration.

Attach the 12 clips and front door trim board retainer to install the front door trim board sub-assembly.

Install the 3 screws.

Attach the 8 claws to install the assist grip cover.

Attach the 3 claws to install the inside handle bezel.

Attach the 2 claws to install the front door lower frame bracket garnish.

Initialize the power window (LandCruiser RM0000011V20BLX.html).

Check the SRS warning light (LandCruiser RM000000XFD0N3X.html).

Adjust the side television camera (LandCruiser RM000003XM401ZX.html).