Toyota 4Runner: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL FRONT DOOR PANEL CUSHION

(a) Attach the claw to install a new front door panel cushion.

2. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE LH

3. INSTALL FRONT DOOR OUTSIDE STRIPE LH

4. INSTALL NO. 1 BLACK OUT TAPE LH

5. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING LH

6. INSTALL FRONT DOOR BELT MOULDING LH

7. INSTALL FRONT DOOR WEATHERSTRIP LH

(a) Attach the 21 clips to install the front door weatherstrip LH.

8. INSTALL FRONT DOOR CHECK ASSEMBLY LH

(a) Apply a few drops of adhesive to 2 or 3 threads of the bolt. Text in Illustration *1 Adhesive Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTICE: Install the bolt within 3 minutes of applying adhesive.

(b) Install the front door check assembly LH to the front door panel with the 2 nuts. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

(c) Install the front door check assembly LH to the vehicle body with the bolt.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

9. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

(a) 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.

(b) Install a new front door No. 2 stiffener cushion.

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

Standard:

Item	Temperature
Front door No. 2 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 front door No. 2 stiffener cushion and vehicle body excessively.

HINT:

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

(2) Remove the peeling paper from the face of the front door No. 2 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. Text in Illustration *1 Double-sided Tape HINT: Press the front door No. 2 stiffener cushion firmly to install it.

(4) Install the 2 bolts.

Torque:

6.2 N·m {63 kgf·cm, 55 in·lbf}

10. INSTALL FRONT DOOR LOCK OPEN ROD LH

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

11. INSTALL FRONT DOOR NO. 2 WIRE LH (w/ Smart Key System)

(a) Attach the 4 clamps to install the front door No. 2 wire LH.

12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

(a) Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly LH.

(b) Attach the door handle nut and claw.

(c) Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly LH with the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(d) w/ Smart Key System:

(1) Attach the clamp.

(2) Connect the connector to the front door No. 2 wire LH.

13. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Install the front door inside locking cable assembly LH to the front door lock assembly LH.

(b) Attach the 3 claws to close the cover.

14. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

(a) Install the front door lock remote control cable assembly LH to the front door lock assembly LH.

15. INSTALL FRONT DOOR LOCK ASSEMBLY LH

16. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD LH

(a) Attach the 2 claws to install the front door rear outside handle pad LH.

17. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD LH

(a) Attach the guide and 2 claws to install the front door front outside handle pad LH.

18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) Insert the front end of the front door outside handle assembly LH into the front door outside handle frame sub-assembly.

(b) Insert the rear end of the front door outside handle assembly LH into the front door outside handle frame sub-assembly. Then slide the front door outside handle assembly LH toward the front of the vehicle to install it.

(c) Move the lever back in the direction indicated by the arrow in the illustration to lock the front door outside handle assembly LH.

(d) w/ Smart Key System:

(1) Connect the connector.

(2) Attach the 2 claws.

19. INSTALL FRONT DOOR OUTSIDE HANDLE COVER RH (for Front Passenger Side)

(a) Using a T30 "TORX" socket wrench, install the front door outside handle cover RH with the screw. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Install the hole plug.

20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH (for Driver Side)

(a) Attach the claw to install the front door outside handle cover LH to the lock cylinder assembly.

21. INSTALL FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)

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

HINT:

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

(b) Using a T30 "TORX" socket wrench, install the front door outside handle cover with lock cylinder assembly with the screw. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Install the hole plug.

22. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY LH

(a) Install the front door rear lower frame sub-assembly LH with the bolt as shown in the illustration. Torque: 6.2 N·m {63 kgf·cm, 55 in·lbf}

23. INSTALL FRONT DOOR GLASS RUN LH

(a) Install the front door glass run LH.

24. INSTALL DOOR FRAME GARNISH LH

(a) Attach the clip to install a new door frame garnish LH.

25. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

(a) Apply MP grease to the sliding parts of the front door window regulator sub-assembly LH.

(b) Install the temporary bolt to the front door window regulator sub-assembly LH. Text in Illustration *1 Temporary Bolt

(c) Temporarily install the front door window regulator sub-assembly LH.

(d) Tighten the temporary bolt and 5 bolts to install the front door window regulator sub-assembly LH.

HINT:

Tighten the bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(e) Connect the connector.

27. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

(a) Connect the multiplex network master switch assembly (for Driver Side).

(b) Connect the power window regulator switch assembly (for Front Passenger Side).

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

(d) Move the front door glass sub-assembly so that the front door glass bolts can be seen.

(e) Disconnect the cable 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.

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).

(f) Disconnect the multiplex network master switch assembly (for Driver Side).

(g) Disconnect the power window regulator switch assembly (for Front Passenger Side).

(h) Insert the front door glass sub-assembly LH into the front door panel along the front door glass run LH as indicated by the arrows in the order shown in the illustration.

(i) Install the front door glass sub-assembly LH with the 2 bolts in the order shown in the illustration. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

28. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

29. INSTALL FRONT DOOR SERVICE HOLE COVER LH

(a) Apply a new butyl tape to the front door panel.

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

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

Text in Illustration

*1	Reference Point

NOTICE:

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

(d) Attach the 2 clamps.

(e) Connect the door wire with the bolt.

30. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH

31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

32. INSTALL SEAT MEMORY SWITCH (w/ Seat Position Memory System)

33. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)

34. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side)

35. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY (for Driver Side)

36. INSTALL COURTESY LIGHT ASSEMBLY LH

37. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY (w/ Intuitive Parking Assist System)

38. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP LH

(a) Attach the 4 claws to install the front door inner glass weatherstrip LH as shown in the illustration.

39. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Connect the front door lock remote control cable assembly LH and front door inside locking cable assembly LH.

(b) Connect the connector.

(c) Attach the front door trim board sub-assembly LH to the 4 claws of the front door inner glass weatherstrip LH as shown in the illustration.

(d) Attach the reference boss.

Text in Illustration

*1	Reference Boss

(e) Attach the 11 clips to install the front door trim board sub-assembly LH.

(f) Install the 3 screws.

(g) Attach the 4 claws to install the 2 door armrest caps.

40. INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL LH

(a) Attach the 3 claws to install the No. 2 door inside handle bezel LH.

41. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

(a) Attach the 2 clips to install the front door lower frame bracket garnish LH.

42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).

43. INITIALIZE POWER WINDOW CONTROL SYSTEM

(See page )

44. CHECK SRS WARNING LIGHT

(See page )