Toyota Tundra Service Manual: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• A bolt without a torque specification is shown in the standard bolt chart (See page ).

PROCEDURE

1. INSTALL FRONT DOOR WEATHERSTRIP LH

(a) Attach the 38 clips to install the weatherstrip. HINT: If clips are damaged during installation, replace them.

2. INSTALL FRONT DOOR CHECK ASSEMBLY LH

(a) Apply MP grease to the sliding areas of the door check.

(b) Install the door check to the door panel with the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(c) Apply adhesive to the threads of the bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the bolt.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

3. INSTALL FRONT DOOR PANEL PROTECTOR LH

(a) Attach the 8 clips to install the door panel protector.

4. INSTALL FRONT NO. 2 DOOR STIFFENER CUSHION

(a) Install the stiffener cushion with the 2 clips.

5. INSTALL FRONT DOOR LOCK OPEN ROD LH

(a) Install the lock open rod to the outside handle frame.

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

(a) Slide the outside handle frame to install it. NOTICE: If the release plate is not pulled and held when installing the outside handle, it will strike against the outside handle and become damaged.

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

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Install the front and rear outside handle pads.

7. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH

(a) Install the handle by pushing it in the direction of the arrow in the illustration. NOTICE: If the bellcrank lever is not pulled and held when installing the handle, the bellcrank lever will interfere with the handle and become damaged.

8. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY LH

(a) Install the front door inside locking cable.

(b) Attach the 3 claws.

9. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY LH

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

10. INSTALL FRONT DOOR LOCK ASSEMBLY LH

(a) Apply MP grease to the sliding and rotating areas of the door lock.

(b) Install a new door lock wire harness packing to the door lock.

NOTICE:

• When reusing a door lock that has been removed, replace the packing in the connecting part with new packing.
• Be careful that no grease or dirt sticks to the packing surface in the connecting part.
• Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.

(c) Using a T30 ''TORX'' wrench, install the door lock with the 3 screws. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(d) Connect the door lock connector.

11. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH

(a) Using a T30 ''TORX'' socket, install the cover (with the door key cylinder) with the screw. Torque: 4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Install the hole plug.

12. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH

(a) Install the frame with the 2 bolts.

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

(a) Install the frame with the 2 bolts.

14. INSTALL FRONT DOOR GLASS RUN LH

(a) Install the front door glass run.

15. INSTALL FRONT OUTER DOOR GLASS WEATHERSTRIP ASSEMBLY LH

16. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH

(a) Install the side airbag sensor with the bolt. Torque: 9.0 N·m {92 kgf·cm, 80 in·lbf}

(b) Connect the connector.

17. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY LH

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

(b) Using a T25 ''TORX'' driver, install the motor with the 3 screws.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

HINT:

For a new front window regulator, the installation position of the regulator will be set when the self-tapping screws are installed.

18. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH

(a) Apply MP grease to the sliding and rotating areas of the window regulator. NOTICE: Do not apply grease to the spring of the window regulator.

(b) Loosely install the temporary bolt onto the window regulator.

(c) Insert the window regulator into the door panel. Use the temporary bolt to hang the window regulator on the door panel.

(d) Temporarily install the window regulator with the 5 bolts, and tighten the temporary bolt so that it contacts the door panel.

(e) Tighten the 6 bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(f) Connect the connector.

19. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

(a) Insert the door glass into the door panel along the glass run as indicated by the arrows in the illustration. NOTICE: Be careful not to damage the glass.

(b) Install the door glass to the window regulator with the 2 bolts. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

20. INSTALL FRONT DOOR SERVICE HOLE COVER LH

(a) Install the front door service hole cover to the door panel.

NOTICE:

• When installing the service hole cover, pull out the links through the service hole cover.
• There should be no wrinkles or folds after attaching the service hole cover.
• After attaching the service hole cover, check the sealing quality.

(b) Connect the connector.

21. INSTALL FRONT NO. 1 DOOR TRIM BRACKET

(a) Install the bracket with the 2 screws.

22. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

23. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH

24. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Power Mirror Control System)

(a) Install the ECU with the 2 screws.

(b) Connect the 2 ECU connectors.

25. INSTALL SEAT MEMORY SWITCH (w/ Seat Memory Switch)

(a) Install the seat memory with the 2 screws.

26. INSTALL FRONT INNER DOOR GLASS WEATHERSTRIP LH

27. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

(a) Connect the 2 cables to the inside handle.

(b) Connect the connector.

(c) Attach the inside handle's knob to the door trim board.

(d) Attach the 9 clips to install the door trim board.

(e) Install the inside handle and door trim board to the door trim panel with the screw.

(f) Install the door trim board to the door panel with the screw.

(g) Install the clip.

28. INSTALL FRONT DOOR ARMREST COVER LH

29. INSTALL FRONT LOWER DOOR FRAME BRACKET GARNISH LH

(a) Attach the 3 clips to install the front door lower frame bracket garnish.

30. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY

31. INSTALL FRONT UPPER ARMREST BASE PANEL LH

(a) Connect the master switch connector.

(b) Attach the 2 clips and 5 claws to install the front upper armrest base panel LH.

32. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG LH

(a) Attach the 4 claws to install the bezel plug.

33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

34. CHECK SRS WARNING LIGHT

(a) Check the SRS warning light (See page ).