Lexus ES: Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch (for Gasoline Model) or power switch (for HV Model) off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

2. INSTALL FRONT DOOR NO. 3 WEATHERSTRIP

(a) Install the front door No. 3 weatherstrip with the 4 clips.

(b) Install the front door panel sub-assembly with the 4 bolts. Torque: 26 N·m {265 kgf·cm, 19 ft·lbf} NOTICE: To prevent damage, when installing the front door panel sub-assembly, make sure that there are enough people available to hold it securely.

(c) Using a brush, apply anti-rust coating to the front door hinge assembly as shown in the illustration.

*A Section *1 Front Door Upper Hinge Assembly *2 Front Door Lower Hinge Assembly *a Front Door Hinge Assembly *b Anti-rust Coating

(d) Connect the connector.

(e) Engage the 4 claws to install the grommet as shown in the illustration. NOTICE: Install the grommet with the arrow facing up.

*a Reference Point

3. INSTALL FRONT DOOR SILENCER PAD

(a) Clean the front door panel surface.

(1) Remove any remaining butyl tape from the front door panel.

(2) Wipe off any tape adhesive residue with cleaner.

(b) Remove the release paper from new front door silencer pad.

HINT:

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

(c) Install the front door silencer pad as shown in the illustration. Installation Position Area Measurement a 0 mm (0 in.) b 20 mm (0.787 in.)

*a Hole Center

4. REPAIR INSTRUCTION

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5. INSTALL FRONT INNER BLACK OUT TAPE

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6. INSTALL FRONT DOOR REAR INNER BLACK OUT TAPE

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7. INSTALL FRONT DOOR REAR OUTSIDE SEAL

(a) Engage the guide to install the front door rear outside seal.

8. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

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9. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

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10. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

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11. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER

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12. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP

(a) Engage the 8 clips to install the front door No. 2 weatherstrip.

13. INSTALL FRONT DOOR PANEL CUSHION

(a) Engage the 4 claws to install 2 new front door panel cushions.

14. INSTALL FRONT DOOR WEATHERSTRIP

(a) Clean the front door panel.

(1) Remove any remaining double-sided tape from the front door panel.

(2) Wipe off any tape adhesive residue with cleaner.

(b) Remove the release paper from a new front door weatherstrip.

HINT:

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

(c) Engage the 23 clips and install a new front door weatherstrip.

Double-sided Tape

15. INSTALL DOOR UPPER FRAME GARNISH

(a) Engage the 3 claws to install the door upper frame garnish.

16. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Clean the bolt hole on the vehicle body.

(b) Clean the threads of the bolt.

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the front door check assembly with the 2 nuts and bolt.

	Nut
	Bolt

Torque:

Bolt :

29 N·m {296 kgf·cm, 21 ft·lbf}

Nut :

8.0 N·m {82 kgf·cm, 71 in·lbf}

17. INSTALL FRONT DOOR LOCK OPEN ROD

(a) Install the front door lock open rod as shown in the illustration.

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

18. 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) Engage the guide and claw as shown in the illustration.

Install in this Direction

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

19. INSTALL FRONT DOOR LOCK WITH MOTOR ASSEMBLY

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20. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 3 guides and claw to install the front door rear outside handle pad.

21. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

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

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

(a) Engage the claw.

(b) Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(c) Install the hole plug.

23. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)

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

(b) Install the hole plug.

24. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

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

Install in this Direction

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

(c) Move the lever as shown in the illustration and engage the 2 claws to secure the front door outside handle assembly.

Engage in this Direction

(d) Engage the 3 clamps.

(e) Connect the connector.

(f) Engage the 2 claws as shown in the illustration.

Engage in this Direction

25. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide as shown in the illustration.

Install in this Direction

(b) Install the front door front lower frame sub-assembly with the 2 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

26. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Engage the guide as shown in the illustration.

Install in this Direction

(b) Install the front door rear lower frame sub-assembly with the 2 bolts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

27. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

28. 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.

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

*a Temporary Bolt

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

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.

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

29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) for Driver Side:

(1) Connect the multiplex network master switch assembly.

(b) for Front Passenger Side:

(1) Connect the power window regulator switch assembly.

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

(d) Turn the engine switch (for Gasoline Model) or power switch (for HV Model) on (IG).

(e) Move the front door window regulator assembly so that the door glass bolt holes can be seen.

(f) Turn the engine switch (for Gasoline Model) or power switch (for HV Model) off.

(g) Disconnect the cable from the negative (-) auxiliary battery terminal.

(h) for Driver Side:

(1) Disconnect the multiplex network master switch assembly.

(i) for Front Passenger Side:

(1) Disconnect the power window regulator switch assembly.

(j) 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)

(k) Install the front door glass sub-assembly with the 2 bolts. Torque: 5.5 N·m {56 kgf·cm, 49 in·lbf}

(l) Install the hole plug.

30. INSTALL FRONT DOOR PANEL PROTECTOR

(a) Install the front door panel protector as shown in the illustration.

Install in this Direction

31. INSTALL FRONT DOOR VENT SEAL

(a) Engage the 2 guides to install the front door vent seal to the front door inner glass weatherstrip as shown in the illustration.

Install in this Direction

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

Install in this Direction

(c) Engage the 2 clips to connect the front door weatherstrip as shown in the illustration.

32. INSTALL DOOR SIDE AIRBAG SENSOR

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33. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Engage the 4 clips to install the front door service hole cover.

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

(c) Engage the 2 clamps.

34. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

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35. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

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36. INSTALL OUTER MIRROR INSTALL HOLE COVER

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37. INSTALL HOLE PLUG

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38. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)

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39. INSTALL FRONT DOOR TRIM BRACKET

(a) Install the front door trim bracket with the 3 screws.

40. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

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

41. INSTALL FRONT DOOR WIRE (w/o Illumination)

(a) w/ Seat Memory Switch:

(1) Connect the connector.

(2) Engage the 3 clamps and claw to install the front door wire.

42. INSTALL FRONT DOOR WIRE (w/ Illumination)

(a) Connect each connector.

*A w/ Seat Memory Switch

(b) Engage the clamp to install the front door wire.

43. INSTALL FRONT NO. 4 SPEAKER ASSEMBLY (for 17 Speakers)

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44. INSTALL FRONT DOOR INSIDE HANDLE ILLUMINATION LIGHT ASSEMBLY (w/ Illumination)

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

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46. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Install the front door inside handle sub-assembly with the 3 screws.

47. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Engage the 2 claws as shown in the illustration to connect the front door inside lock/unlock knob locking cable to the front door trim board sub-assembly.

Install in this Direction

(b) Connect the front door lock open lever remote control cable as shown in the illustration.

Install in this Direction

(c) w/ Seat Memory Switch or w/ Illumination:

(1) Connect the connector.

(d) for 17 Speakers:

(1) Connect the connector.

(e) Engage the guide, 4 claws and 11 clips as shown in the illustration.

Install in this Direction

(f) Install the front door trim board sub-assembly with the 3 screws.

(g) Engage the 2 claws as shown in the illustration.

48. INSTALL COURTESY LIGHT ASSEMBLY

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

(a) Connect the connector.

(b) Engage the 3 guides, 5 claws and 2 clips to install the multiplex network master switch assembly with front door upper armrest base panel as shown in the illustration.

Install in this Direction

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

(a) Connect the connector.

(b) Engage the 4 guides, 5 claws and 2 clips to install the power window regulator switch assembly with front door upper armrest base panel as shown in the illustration.

Install in this Direction

51. INSTALL NO. 2 DOOR TRIM PAD

(a) Engage the 2 claws to install the No. 2 door trim pad.

52. INSTALL BOX BOTTOM MAT (w/ Illumination)

(a) Install the box bottom mat.

53. INSTALL DOOR ARMREST COVER

(a) Install the door armrest cover.

54. ADJUST FRONT DOOR

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55. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

for 2GR-FKS:

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for A25A-FXS:

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for A25A-FKS:

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56. INITIALIZE POWER WINDOW CONTROL SYSTEM

for Gasoline Model:

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for HV Model:

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57. INSPECT POWER WINDOW OPERATION

for Gasoline Model:

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for HV Model:

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58. PERFORM CALIBRATION (w/ Panoramic View Monitor System)

for Gasoline Model:

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for HV Model:

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59. INSPECT SRS WARNING LIGHT

for Gasoline Model:

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for HV Model:

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