Front Door (For Sedan) Reassembly

Install the 2 cushions onto the door panel.

Install the front door stiffener cushion with the bolt.

Torque:

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

Engage the 35 clips and install the front door weatherstrip.

Apply MP grease to the sliding areas of the 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.

NOTICE:

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}

Slide the door outside handle protector to install it.

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}

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

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

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 and rotating areas of the front door lock.

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

Close the cover.

Insert the door lock open rod into the front door lock, then set it to the door panel.

NOTICE:

Make sure that the outside handle link is securely engaged with the door lock.

Apply adhesive to the threads of the screws.

NOTICE:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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}

Using "Torx" socket wrench T30, install the cover with the door lock key cylinder.

Torque:

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

HINT:

Make sure that the door lock key cylinder rod is inserted.

Install the hole plug.

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

Torque:

6.2 N*m{63 kgf*cm, 54 in.*lbf}

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

Torque:

6.2 N*m{63 kgf*cm, 54 in.*lbf}

Install the front door glass run, then engage the clip.

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

Using "Torx" socket wrench T25, install the power window regulator motor assembly front with the 3 screws.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Apply MP grease to the sliding and rotating areas of the front door window regulator.

NOTICE:

Do not apply grease to the window regulator spring.

w/ Power window:

1. Loosely screw bolt A onto the front door window regulator.
   

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

   NOTICE:

   Do not drop the window regulator as it may be damaged.

3. Install the front door window regulator with the 5 bolts, and tighten bolt A.
   

   Torque:

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

4. Connect the connector.
   

w/o Power window:

1. Loosely screw bolt A onto the front door window regulator.
   

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

   NOTICE:

   Do not drop the window regulator as it may be damaged.

3. Install the front door window regulator with the 5 bolts, and tighten bolt A.
   

   Torque:

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

4. Connect the connector.
   

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

NOTICE:

Do not damage the glass.

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}

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

Specification:

Area	Dimension
A	2.0 mm (0.079 in.) or more
B	6.0 mm (0.236 in.) or more

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.
   

Install the front door trim bracket with the 2 screws.

Engage the 6 claws and install a new front door belt moulding.

Remove the protective tape.

Engage the claw and install the outer rear view mirror with the 3 nuts.

Torque:

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

w/ Power mirror:
Connect the connector.

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 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 speaker connector.

Install the front door glass weatherstrip inner onto the front door trim board.

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

w/ Power window:

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





2. Engage the 9 clips and install the front door trim board.
   





3. Tighten the screw.
   

w/o Power window:

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





2. Engage the 9 clips and install the front door trim board.
   





3. Tighten the screw.
   

Install the power window regulator master switch with the 3 screws.

Engage the 2 claws and install the power window regulator switch.

Engage the 2 claws and install the door control switch.

for Driver side with power window:

1. Connect the connector.
   

2. Engage the 7 claws and 2 clips and install the front armrest base upper panel.
   

3. Tighten the screw.
   

for Front passenger side with power window:

1. Connect the connector.
   

2. Engage the 7 claws and 2 clips and install the front armrest base upper panel.
   

3. Tighten the screw.
   

w/o Power window:

1. Engage the 5 clips and 2 clips and install the front armrest base upper panel.
   

2. Tighten the screw.
   

Engage the claw and clip and install the front door lower frame bracket garnish.

Install the window regulator handle plate.

Open all the windows.

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