Front Door Reassembly

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

When reusing a bolt labeled B:

1. Clean the threads of the bolt labeled B with non-residue solvent.
   

2. Apply adhesive to the threads of the bolt labeled B.
   

   Adhesive:

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
   

Install the front door check with the 2 bolts labeled A and the bolt labeled B.

Torque:

Bolt A:

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

Bolt B:

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

Clean the front door panel surface.

1. Using a heat light, heat the front door panel surface.
   

2. Remove the double-sided tape from the front door panel surface.
   

3. Wipe off any tape adhesive residue with cleaner.
   

Install a new front door weatherstrip.

1. for Double Cab:
   

   1. Remove the peeling paper from the face of the front door weatherstrip.
      

      HINT:

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

   2. Attach the 33 clips to install the front door weatherstrip.
      

      HINT:

      Press the front door weatherstrip firmly to install it.

   3. Install the clip.
      

2. for Single Cab:
   

   1. Remove the peeling paper from the face of the front door weatherstrip.
      

      HINT:

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

   2. Attach the 34 clips to install the front door weatherstrip.
      

      HINT:

      Press the front door weatherstrip firmly to install it.

   3. Install the clip.
      

Install a new front door panel cushion.

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

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

Install the front door lock open rod to the front door outside handle frame.

Rotate the snap in the direction indicated by the arrow in the illustration to attach the snap to the front door lock open rod.

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

Attach the claw to install the front door outside handle frame.

Using a T30 "TORX" socket wrench, install the screw.

Torque:

4.0 N*m{41 kgf*cm, 36 in.*lbf}

Install the front door outside handle by moving it in the direction indicated by the arrow shown in the illustration.

Install the front door inside locking cable.

Attach the 3 claws to close the cover.

Install the front door lock remote control cable.

w/ Power Door Lock:
(HILUX_TGN26 RM00000138T019X_01_0007.html)

w/o Power Door Lock:

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

   Torque:

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

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

Attach the 2 claws to install the front door outside handle cover to the door key cylinder.

Using a T30 "TORX" socket wrench, install the front door outside handle cover together with the door key cylinder with the screw.

Torque:

4.0 N*m{41 kgf*cm, 36 in.*lbf}

Install the hole plug.

Install the front door rear lower frame with the 2 nuts.

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 assembly LH with the 3 screws.

Torque:

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

w/ Power Window:

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

2. Temporarily install the temporary bolt to the front door window regulator.
   





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

   Torque:

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

   Text in Illustration

   *1	Temporary Bolt

   NOTICE:

   Be careful not to drop the front door window regulator as it may become damaged.

4. Connect the connector.
   

w/o Power Window:

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

   NOTICE:

   Do not apply grease to the spring of the window regulator.

2. Temporarily install the temporary bolt to the front door window regulator.
   





3. Install the front door window regulator with the 4 bolts, and then tighten the temporary bolt.
   

   Torque:

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

   Text in Illustration

   *1	Temporary Bolt

   NOTICE:

   Be careful not to drop the front door window regulator as it may become damaged.

Install the front door glass run.

Attach the 5 claws to install the front door outer glass weatherstrip.

w/ Power Window:

1. Temporarily install the power window regulator master switch assembly with front door armrest base panel.
   

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

3. Operate the front door window regulator so that the front door glass can be installed.
   

4. Disconnect the cable from the negative (-) battery terminal.
   

   NOTICE:

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3003X.html).

5. Remove the power window regulator master switch assembly with front door armrest base panel.
   

w/o Power Window:

1. Temporarily install the front door window regulator handle.
   

2. Operate the front door window regulator so that the front door glass can be installed.
   

3. Remove the front door window regulator handle.
   

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.

Install the front door glass with the 2 bolts.

Torque:

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

Apply new butyl tape to the front door panel.

Pass the front door inside locking cable, front door lock remote control cable and wire harness through a new front door service hole cover, and then install the front door service hole cover using the reference points on the front door panel.

Install the front door No. 1 trim bracket with the 2 screws.

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

Attach the 2 guides as indicated by the arrow in the illustration, and then attach the claw to install the front door inside handle.

Attach the claw and install the outer rear view mirror assembly LH with the 3 nuts.

Torque:

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

w/ Power Mirror Control System:
Connect the connector.

Install a nose piece to an air riveter or hand riveter. Then insert the mandrel part of a new φ4 mm waterproof rivet into the nose piece.

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

NOTICE:

1. Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
   

   Text in Illustration

   *a	INCORRECT
   *b	CORRECT
   *1	Mandrel
   *2	Riveter



2. Confirm that the rivets are seated properly against the speaker.
   

   Text in Illustration

   *a	INCORRECT
   *b	CORRECT
   *1	Riveter

3. Do not tilt the riveter when installing the rivet to 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.
   

   Text in Illustration

   *a	INCORRECT
   *b	CORRECT
   *1	Riveter

Connect the connector.

Install the front No. 2 speaker assembly with the screw.

Connect the connector.

for Double Cab:

1. Install the front door inner glass weatherstrip to the front door trim board and fold down the 7 claws in the directions indicated by the arrows in the illustration.
   

for Single Cab:

1. Install the front door inner glass weatherstrip to the front door trim board and fold down the 8 claws in the directions indicated by the arrows in the illustration.
   

for Double Cab:

1. Attach the 8 clips to install the front door trim board.
   

2. Install the screw and clip.
   

for Single Cab:

1. Attach the 9 clips to install the front door trim board.
   

2. Install the screw and clip.
   

Install the door pull handle with the screw.

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

Connect the connector.

Attach the 4 claws and 2 clips to install the power window regulator switch assembly with front door armrest base panel.

Connect the connector.

Attach the 4 claws and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.

Temporarily install the front door window regulator handle, fully close the window, and then remove the front door window regulator handle.

Install the plate and snap ring to the front door window regulator handle.

Install the front door window regulator handle to the front door window regulator as shown in the illustration.

Standard:

Area	Specified Condition
A	18 to 42°