RX400h · Service Manual BODY

REASSEMBLY

Removal / installation


1. INSTALL FRONT WINDOW FRAME MOULDING REAR

  1. B068607E01
    Remove the tape from the moulding.

  1. Clean the contact surface of the body with white gasoline.

  1. Clean the outer circumference of the moulding with white gasoline.

  1. Apply new double-sided tape to the moulding, as shown in the illustration.

    Dimension:
    A
    		 400.0 mm (15.748 in.)
    B
    		 5.0 mm (0.197 in.)
    C
    		 1.2 mm (0.047 in.)

  1. Using a heat light, heat the body and moulding.

    Heating temperature:
    Body
    		 40 to 60°C (104 to 140°F)
    Moulding
    		 20 to 30°C (68 to 86°F)

    NOTICE:
    Do not heat the body and moulding excessively.

  1. Remove the release paper from the moulding face.

    HINT:
    Be careful that dirt or foreign objects do not stick to the adhesive part when removing the release paper.

  1. Engage the 2 claws and install the moulding with the screw.

    NOTICE:
    Do not apply excessive force onto the moulding, but apply steady pressure with your thumbs.


2. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

3. INSTALL FRONT DOOR WEATHERSTRIP

4. INSTALL FRONT DOOR CHECK ASSEMBLY

  1. B112330
    Install the front door check assembly with the bolt and the 2 nuts.

    Torque:
    bolt:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }

    Torque:
    nut:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }


5. INSTALL FRONT DOOR CHECK COVER

6. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

  1. Apply body grease to the sliding parts on the front door outside handle frame sub-assembly.

  1. B112328
    Install the front door outside handle frame sub-assembly with the claw.

  1. B116248E01
    Using a "torx" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }


7. INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR

8. INSTALL FRONT DOOR OUTSIDE HANDLE PAD

9. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE

10. INSTALL FRONT DOOR OUTSIDE HANDLE COVER

  1. B061438
    Using a "torx" socket wrench (T30), install the front door outside handle cover with the screw.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }

  1. Install the hole plug.


11. INSTALL DOOR LOCK WIRING HARNESS SEAL

12. INSTALL FRONT DOOR LOCK ASSEMBLY

NOTICE:
  1. When reusing the removed front door lock assembly, replace the door lock wire harness sealing on the connector with a new one.
  2. Do not allow grease or dust to adhere on the door lock wiring harness sealing surface of the connector.
  3. Reusing the door lock wiring harness sealing and/or using damaged door lock wiring harness sealing may cause water intrusion to the connection, and result in a malfunction in the front door lock assembly.

  1. Apply body grease to the sliding parts on the front door lock assembly.

  1. B112323E01
    Insert the front door outside handle link to the front door lock assembly, and set it to the front door panel.

  1. Make sure that the front door outside handle link is securely connected to the front door lock assembly.

  1. Using a "torx" socket wrench (T30), install the front door lock assembly with the 3 screws.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Connect the connector.


13. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER

14. INSTALL POWER WINDOW REGULATOR MOTOR SUB-ASSEMBLY FRONT

NOTICE:
The regulator arm must be below the intermediate position when installing the power window regulator motor.

  1. B112321
    Using a "torx" driver (T25), install the power window regulator motor sub-assembly front with the 3 screws.

    Torque:
    5.5 N*m{ 56 kgf*cm , 49 in.*lbf }

    HINT:
    The new front window regulator adopts a self-tapping method. The installation position of regulator will be threaded when the self-tapping screw is inserted.


15. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

  1. Apply body grease to the sliding parts on the front door window regulator sub-assembly.

  1. B112320E01
    Install the temporary bolt to the front door window regulator sub-assembly.

  1. Temporarily install the window regulator.

  1. Install the front door window regulator sub-assembly with the 6 bolts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

  1. Connect the connector.


16. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

  1. B112319
    Install the front door glass sub-assembly with the 2 bolts.

    Torque:
    5.5 N*m{ 56 kgf*cm , 49 in.*lbf }


17. INSTALL FRONT DOOR GLASS RUN

18. INSTALL FRONT DOOR SERVICE HOLE COVER

  1. B068815E01
    Apply butyl tape to the front door panel as shown in the illustration.

  1. Install a new service hole cover.


19. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

  1. B112347
    Install the outer rear view mirror assembly with the 3 bolts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

  1. Connect the connector and install the clamp.


20. INSTALL FRONT NO.1 SPEAKER ASSEMBLY

  1. E111303
    Install the front No.1 speaker with the 4 bolts.

  1. Connect the connector.


21. INSTALL FRONT DOOR ARMREST SET BRACKET

22. INSTALL FRONT DOOR GLASS WEATHERSTRIP INNER

23. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

  1. Connect each connector and the cables.

  1. B112314E02
    Install the front door trim board sub-assembly with the 15 clips <B>.

  1. Install the 2 screws and the clip <A>.

    Torque:
    screw <A>:
    3.5 N*m{ 36 kgf*cm , 31 in.*lbf }


24. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

25. INSTALL DOOR ARMREST COVER

26. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY

27. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

28. POWER WINDOW CONTROL SYSTEM INITIALIZATION
(Click here)
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