Toyota CH-R Service Manual: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL NO. 2 FRONT DOOR STRIPE

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2. INSTALL FRONT DOOR OUTSIDE STRIPE

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3. INSTALL NO. 4 FRONT DOOR STRIPE

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4. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

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5. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING

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6. INSTALL COWL SIDE TRIM BOARD

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7. INSTALL FRONT DOOR SCUFF PLATE

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8. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

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9. INSTALL HOLE CAP

(a) Install the hole cap.

10. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

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11. INSTALL FRONT DOOR OUTSIDE MOULDING

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12. INSTALL FRONT DOOR PANEL CUSHION

(a) Engage the claws to install the 2 front door panel cushions.

13. INSTALL FRONT DOOR FIX WINDOW WEATHERSTRIP

(a) Install the front door fix window weatherstrip to the front door fix window glass.

14. INSTALL FRONT DOOR FIX WINDOW GLASS

(a) Install the front door fix window glass with front door fix window weatherstrip as shown in the illustration.

Install in this Direction

15. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

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16. INSTALL FRONT DOOR DUST PROOF SEAL

(a) Install the 3 front door dust proof seals.

17. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the clip (A) and other clip to install the front door weatherstrip.

*a Clip (A)

18. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Apply MP grease to the sliding parts of the front door check assembly.

(b) Clean the bolt hole in the vehicle body.

(c) Clean the threads of the bolt (A).

(d) Apply adhesive to the threads of the bolt (A).

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(e) Install the front door check assembly with the bolt (A) and 2 bolts (B). Torque: Bolt (A) : 30 N·m {306 kgf·cm, 22 ft·lbf} Bolt (B) : 5.5 N·m {56 kgf·cm, 49 in·lbf}

*a Bolt (A) *b Bolt (B)

19. INSTALL FRONT DOOR LOCK OPEN ROD

(a) Engage the snap to install the front door lock open rod to the front door outside frame sub-assembly as shown in the illustration.

*a	Snap
	Install in this Direction (1)
	Install in this Direction (2)

20. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

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

(b) w/ Smart Key System:

(1) Engage the clamps and guide.

*a Guide *b Clamp

(2) Engage the grommet and guides to install the front door outside handle frame sub-assembly as shown in the illustration.

*a	Grommet
*b	Guide
	Install in this Direction

(3) Using a T30 "TORX" socket wrench, tighten the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) w/o Smart Key System:

(1) Engage the grommet and guides to install the front door outside handle frame sub-assembly as shown in the illustration.

*a	Grommet
*b	Guide
	Install in this Direction

(2) Using a T30 "TORX" socket wrench, tighten the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

21. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

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22. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the guides to install the front door rear outside handle pad as shown in the illustration.

Install in this Direction

23. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the guide and claws to install the front door front outside handle pad as shown in the illustration.

Install in this Direction

24. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

(a) Install the front door outside handle assembly as shown in the illustration.

Install in this Direction

(b) w/ Smart Key System: (1) Connect the connector. (2) Engage the claws.

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

(a) Engage the claws to install the front door outside handle cover as shown in the illustration.

*1	Hole Plug
	Remove in this Direction

(b) Using a T30 "TORX" socket wrench, tighten the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Install the hole plug.

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

(a) Engage the guides and claw to install the front door outside handle cover as shown in the illustration.

Install in this Direction

(b) Apply MP grease to the sliding area of the front door lock cylinder assembly.

(c) Install the front door outside handle cover with lock cylinder assembly as shown in the illustration.

*1	Hole Plug
	Install in this Direction

HINT:

Check that the front door lock cylinder assembly is inserted into the front door lock with motor assembly.

(d) Using a T30 "TORX" socket wrench, tighten the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(e) Install the hole plug.

27. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide to install the front door rear lower frame sub-assembly.

Install in this Direction

(b) Install the bolt.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

28. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Install the front door front lower frame sub-assembly with the 2 bolts. Torque: 8.5 N·m {87 kgf·cm, 75 in·lbf}

(b) Raise up the front door weatherstrip.

(c) Install the screw.

(d) Install the front door weatherstrip.

29. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

30. INSTALL DOOR FRAME UPPER GARNISH

(a) Engage the guides to install the door frame upper garnish.

31. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY

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

(b) Temporarily install the temporary bolt to the front door window regulator assembly.

*a Temporary Bolt

(c) Temporarily install the front door window regulator assembly with the 5 bolts.

(d) Tighten the temporary bolt and 3 bolts to install the front door window regulator assembly.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

HINT:

Tighten the bolts in the order shown in the illustration.

(e) Tighten the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(f) Connect the connector.

32. INSTALL NO. 2 FRONT DOOR SERVICE HOLE COVER

(a) Engage the claws to install the No. 2 front door service hole cover.

33. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) for Driver Side:

(1) Connect the power window regulator master switch assembly.

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

(3) Move the front door glass sub-assembly so that the door glass bolt holes can be seen.

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

(5) Disconnect the power window regulator master switch assembly.

(b) for Front Passenger Side:

(1) Connect the power window regulator switch assembly.

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

(3) Move the front door glass sub-assembly so that the door glass bolt holes can be seen.

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

(5) Disconnect the power window regulator switch assembly.

(c) Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.

	Install in this Direction (1)
	Install in this Direction (2)

NOTICE:

Be careful not to damage the front door glass sub-assembly.

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

(e) Install the hole plug.

34. INSTALL DOOR SIDE AIRBAG SENSOR (w/ Airbag Sensor)

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35. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Engage the clips to install the front door service hole cover.

(b) Insert the 3 front door weatherstrip clips and turn them 45° as shown in the illustration.

36. INSTALL OUTER MIRROR PROTECTOR

(a) Engage the claws to install the outer mirror protector as shown in the illustration.

Install in this Direction

(b) Install the 2 screws.

37. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

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38. INSTALL FRONT DOOR VENT SEAL

(a) Install the front door vent seal.

39. INSTALL FRONT DOOR BELT SEAL

(a) Install the front door belt seal to the front door glass inner weatherstrip as shown in the illustration.

Install in this Direction

40. INSTALL FRONT DOOR GLASS INNER WEATHERSTRIP

(a) Install the front door glass inner weatherstrip with the front door belt seal as shown in the illustration.

Install in this Direction

41. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Engage the clips to install the front door lower frame bracket garnish.

42. INSTALL NO. 1 INTERIOR ILLUMINATION LIGHT ASSEMBLY (w/ Illumination)

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43. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the claw and guides to install the front door inside handle sub-assembly.

44. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Engage the guides to connect the front door lock remote control cable assembly and front door inside locking cable assembly as shown in the illustration.

*1	Front Door Inside Locking Cable Assembly
*2	Front Door Lock Remote Control Cable Assembly
	Install in this Direction

(b) w/ Illumination:

(1) Connect the connector.

(c) Engage the claws as shown in the illustration.

Install in this Direction

(d) Engage the clip (A), other clips and guide to install the front door trim board sub-assembly.

*a Clip (A)

(e) Install the 3 screws.

45. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT ARMREST BASE UPPER PANEL (for Driver Side)

(a) Connect the 2 connectors.

(b) Engage the guides, clips and claws to install the multiplex network master switch assembly with front door upper armrest base panel as shown in the illustration.

Install in this Direction

46. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT ARMREST BASE UPPER PANEL (for Front Passenger Side)

(a) w/o Rear Seat Side Airbag:

(1) Connect the connector.

(b) w/ Rear Seat Side Airbag:

(1) Connect the 2 connectors.

(c) Engage the guides, clips and claws to install the power window regulator switch assembly with front door upper armrest base panel as shown in the illustration.

Install in this Direction

47. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

(a) Engage the claws to install the front door inside handle bezel plug as shown in the illustration.

Install in this Direction

48. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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49. INITIALIZE POWER WINDOW CONTROL SYSTEM

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50. INSPECT POWER WINDOW OPERATION

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51. INSPECT SRS WARNING LIGHT (w/ Airbag Sensor)

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