Front Door (For Hatchback) Reassembly

Install the 2 cushions onto the door panel.

Engage the 29 clips and install the front door weatherstrip.

Engage the clip.

Engage the 32 clips and install the front door weatherstrip.

Engage the clip.

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

Install the front door check onto the door panel with the 2 bolts.

Torque:

5.5 N*m{56 kgf*cm, 49 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 onto the body panel with the bolt.

Torque:

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

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

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

Slide the front door outside handle frame to install it.

Engage the grommet and 2 claws.

Using a "TORX" socket wrench T30, install the front door outside handle frame with the screw.

Torque:

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

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

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

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

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

Install the door lock wire harness seal to the front door lock.

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

Text in Illustration

*1	Front Door Lock Open Rod
	Slide Direction

HINT:

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

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

Torque:

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

Connect the connector.

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

Install the door lock wire harness seal to the front door lock.

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

Text in Illustration

*1	Front Door Lock Open Rod
	Slide Direction

HINT:

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

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

Torque:

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

Engage the 2 guides.

Engage the claw and install the front door outside handle cover.

Temporarily install the front door outside handle cover.

Using a "TORX" socket wrench T30, install the front door outside handle cover.

Torque:

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

Install the hole plug.

Install the front door fix window glass onto the front door fix window weatherstrip.

Slide the front door fix window weatherstrip, in the direction indicated by the arrow in the illustration, to install it.

Install the front door front lower frame with the 2 bolts and screw.

Torque:

Bolt:

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

Engage the guide.

Install the front door rear lower frame with the bolt.

Torque:

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

Install the front door glass run.

Using a piece of cloth or similar material, rub off any double-sided tape remaining on the door panel.

Using a non-residue solvent, clean the attachment surface.

Remove the double-sided tape backing of the new front door No. 1 stiffener cushion.

Install the front door No. 1 stiffener cushion with the 2 bolts.

Torque:

6.3 N*m{64 kgf*cm, 55 in.*lbf}

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

Install the temporary bolt.

Insert the front door window regulator into the door panel. Use the temporary bolt to hang the front door window regulator on the door panel.

Tighten the 3 bolts and the temporary bolt in the order shown in the illustration.

Torque:

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

Install the front door window regulator with the 2 bolts.

Torque:

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

Connect the connector.

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

Install the temporary bolt.

Insert the front door window regulator into the door panel. Use the temporary bolt to hang the front door window regulator on the door panel.

Tighten the 2 bolts and temporary bolt in the order shown in the illustration.

Torque:

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

Install the front door window regulator with the 2 bolts.

Torque:

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

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

Connect the power window regulator master switch and move the front door glass so that the door glass bolt holes can be seen.

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

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

NOTICE:

Do not damage the front door glass.

Install the front door glass with the 2 bolts.

Torque:

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

Install the front door service hole cover.

Apply butyl tape to the front door panel.

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

Install a new front door service hole cover according to the reference points on the front door panel.

HINT:

Securely install the front door service hole cover taking care to prevent wrinkles.

Apply butyl tape to the front door panel.

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

Install a new front door service hole cover according to the reference points on the front door panel.

HINT:

Securely install the front door service hole cover taking care to prevent wrinkles.

Using an air riveter or hand riveter, install the front No. 1 speaker assembly onto the front door panel 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 onto 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 the 2 items together while installing the rivet.
   

Connect the connector.

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.

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

Torque:

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

NOTICE:

1. If the door side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one.
   
2. When installing the door side airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts.
   
3. Make sure that the pin (stopper) is securely inserted into the body hole.
   
4. Tighten the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.
   

Connect the connector to the door side airbag sensor.

NOTICE:

When connecting any airbag connector, take care not to damage the airbag wire harness.

1. Connect the connector as shown in the illustration (when locking, make sure that the outer connector locking sleeve returns to its original position and a click sound can be heard).
   
   

   
   
   
   
   

   Text in Illustration

   *1	Outer Connector Locking Sleeve	-	-
   *a	Slide	-	-

   HINT:

   When connected, the outer connector locking sleeve will slide. Be sure not to hold the outer connector locking sleeve while connecting, as it may result in an insecure fit.

Check that there is no looseness in the installation parts of the door side airbag sensor.

Engage the 7 claws and install the front door glass inner weatherstrip as shown in the illustration.

Engage the 8 claws and install the front door glass inner weatherstrip as shown in the illustration.

Engage the 4 guides and install the front door inside handle.

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

Engage the 7 clips and the front door trim board.

Install the 3 screws.

Engage the claw and close the cover.

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

Engage the 8 clips and the front door trim board.

Install the 3 screws.

Engage the claw and close the cover.

Connect the connector.

Engage the 9 claws and 4 guides, and install the front armrest base upper panel.

Connect the connector.

HINT:

If the armrest base upper panel is equipped with door lock switch, connect the connector.

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

Install the window regulator handle plate.

Open all the windows.

Install the front door window regulator handle with clip at the angle shown in the illustration.