Toyota CH-R Service Manual: Installation

INSTALLATION

CAUTION / NOTICE / HINT

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. INSTALL FRONT DOOR FRONT WINDOW FRAME MOULDING

(a) Using an air riveter or hand riveter with a nose piece, install the front door front window frame moulding with 2 new rivets.

NOTICE:

To prevent damage, when installing the front door front window frame moulding, make sure that there are enough people available to hold it securely.

HINT:

If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

NOTICE:

  • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

    *a

    Riveter

    *b

    Mandrel

    *c

    Incorrect

  • Confirm that the rivets are seated properly against the moulding.

    *a

    Riveter

    *b

    Incorrect

  • Do not tilt the riveter when installing the rivet to the moulding.
  • Do not leave any space between the rivet head and moulding.
  • Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

    *a

    Riveter

    *b

    Incorrect

(b) Install the front door panel sub-assembly with the 4 bolts <A>.

Torque:

for TMMT Made :

26 N·m {265 kgf·cm, 19 ft·lbf}

for TMC Made :

21 N·m {214 kgf·cm, 15 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.

*a

Bolt <A>

*b

Bolt <B>

(c) Install the bolt <B>.

Torque:

30 N·m {306 kgf·cm, 22 ft·lbf}

(d) Using a brush, apply anti-rust coating to each 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

(e) Connect each connector.

(f) Engage each clamp.

2. INSTALL COWL SIDE TRIM BOARD

Click here

3. INSTALL FRONT DOOR SCUFF PLATE

Click here

4. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

(a) Engage the guide to temporarily install the front door upper window frame moulding to the door frame.

(b) Using an air riveter or hand riveter with a nose piece, install the front door upper window frame moulding with 6 new rivets.

HINT:

If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

NOTICE:

  • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

    *a

    Riveter

    *b

    Mandrel

    *c

    Incorrect

  • Confirm that the rivets are seated properly against the moulding.

    *a

    Riveter

    *b

    Incorrect

  • Do not tilt the riveter when installing the rivet to the moulding.
  • Do not leave any space between the rivet head and moulding.
  • Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

    *a

    Riveter

    *b

    Incorrect

5. INSTALL FRONT DOOR FIX WINDOW GLASS

Click here

6. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

Click here

7. INSTALL FRONT DOOR GLASS RUN

Click here

8. INSTALL DOOR FRAME UPPER GARNISH

Click here

9. CONNECT FRONT DOOR WEATHERSTRIP

(a) Engage the clips to connect the front door weatherstrip.

10. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

HINT:

When installing a new front door outside moulding sub-assembly, heat the vehicle body and front door outside moulding sub-assembly using a heat light.

Heating Temperature

Item

Temperature

Vehicle Body

40 to 60°C (104 to 140°F)

Front Door Outside Moulding Sub-assembly

20 to 30°C (68 to 86°F)

CAUTION:

  • Do not touch the heat light and heated parts, touching the heat light may result in burns.
  • Touching heated parts for a long time may result in burns.

*a

Heated Part

*b

Heat Light

NOTICE:

Do not heat the vehicle body or front door outside moulding sub-assembly excessively.

(a) Clean the vehicle body surface.

(1) Using a heat light, heat the vehicle body surface.

(2) Remove any double-sided tape from the vehicle body.

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

(b) Install a new front door outside moulding sub-assembly.

*a

Double-sided Tape

Install in this Direction (1)

Install in this Direction (2)

(1) Using a heat light, heat the vehicle body and front door outside moulding sub-assembly.

(2) Remove the release paper from the front door outside moulding sub-assembly.

HINT:

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

(3) Engage the guide and clip and attach the double-sided tape and caulking sponge to install the front door outside moulding sub-assembly.

HINT:

Press the front door outside moulding sub-assembly firmly to install it.

(c) Remove the protective tape.

11. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

Click here

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