Section 1023 (Front Door): Reassembly

WARNING: This page is about a different car, the 2004 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL OUTER WEATHERSTRIP
INSTALL CUSHIONS
INSTALL OUTSIDE HANDLE AND KEY CYLINDER
1. Install the key cylinder and protector with the bolt to the outside handle.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
2. Install the retainer to the outside handle.
3. Install the outside handle with the key cylinder to the door panel with the 2 bolts.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  
  Fig 1: Installing Outside Handle With Key Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the hole cover with the screw.
INSTALL DOOR LOCK
1. Connect the connector.
2. Using a torx socket wrench, install the door lock with the 3 torx screws.
  - Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
  - Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
  Fig 2: Installing Door Lock
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Apply adhesive to the 3 torx screws.
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
3. Install the bolt and 2 screws.
4. Connect the 2 links to the outside handle and key cylinder.
INSTALL REAR LOWER FRAME
Install the rear lower frame with the bolt.
INSTALL DOOR GLASS RUN
INSTALL WINDOW REGULATOR MOTOR
1. Align the matchmarks on the regulator motor bracket and regulator gear.
2. Install the 3 screws.
NOTE: Driver's side:
If only the motor is rotated, reset the motor (See ADJUSTMENT ).

NOTE: Driver's side:
Never rotate the motor to the down direction mention of the window glass until completing the installation.
INSTALL WINDOW REGULATOR
HINT:

Apply MP grease to the sliding and rotating parts of the window regulator.

Fig 3: Applying MP Grease To Sliding & Rotating Parts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the window regulator with the 6 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 4: Installing Window Regulator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the connector and attach the clamps.
INSTALL DOOR GLASS
NOTE: Do not damage the door glass.
1. Put the door glass in the door panel carefully.
2. Install the door glass with the 2 bolts to the window regulator.
  Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
Fig 5: Installing Door Glass
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DOOR BELT MOLDING
Install the front door belt molding with the screw.

Fig 6: Installing Front Door Belt Molding
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 SERVICE HOLE COVER
Install the No.2 service hole cover with the 2 screws.
INSTALL FRONT DOOR INSIDE PANEL PLATE
Install the front door inside panel plate with the 2 screws.

Fig 7: Installing No. 2 Service Hole Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SERVICE HOLE COVER
1. Install the service hole cover to the door panel.
  
  Fig 8: Installing Service Hole Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  - When installing the service hole cover, pull out the links and the connectors through the service hole cover.
  - There should be no wrinkles or folds after attaching the service hole cover.
  - After attaching the service hole cover, sealing condition should be confirmed.
2. Install the door trim bracket with the 2 screws.
INSTALL INSIDE HANDLE
Connect the 2 cables to the inside handle, then install the inside handle with the screw.

Fig 9: Installing Inside Handle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:
At the time of locking cable reassembly, please refer to the following items.
- Set the door lock assembly to the LOCK position.
- Hold the lock knob to the LOCK position by hand, and do not pull the cable while connecting the locking cable.
INSTALL FRONT NO.1 SPEAKER
1. Using an air riveter or hand riveter, install the front No.1 speaker.
  
  Fig 10: Installing Front Speaker Using Hand Riveter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.
    
    Fig 11: Correct Way Using Riveter (1 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not tilt the riveter when fastening the rivet to the material to avoid loose fitting.
  - Do not allow gap spacing between the rivet head and the material.
    
    Fig 12: Correct Way Using Riveter (2 Of 3)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not allow gap spacing between the materials.
  Fig 13: Correct Way Using Riveter (3 Of 3)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the connector.
INSTALL OUTSIDE REAR VIEW MIRROR
1. Install the outside rear view mirror with the bolt.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
2. Connect the connector.
INSTALL FRONT NO.2 SPEAKER
1. Install the front No.2 speaker with the 2 bolts.
  Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
  
  Fig 14: Installing Front Speaker
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 2 connectors.
INSTALL DOOR TRIM
1. Install the door trim to the door panel.
  
  Fig 15: Installing Door Trim To Door Panel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the connector, then install the courtesy light.
INSTALL LOWER FRAME BRACKET GARNISH
Install the lower frame bracket garnish to the door panel.

Fig 16: Installing Lower Frame Bracket Garnish
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT ARMREST
Install the front armrest with the screw.

Fig 17: Installing Front Armrest
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER WINDOW SWITCH
1. Connect the connectors.
2. Install the power window switch.
INSTALL INSIDE HANDLE BEZEL
1. Install the inside handle bezel with the screw.
2. Close the screw cap.
Fig 18: Installing Inside Handle Bezel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002