Front Door: Service and Repair
DISASSEMBLY
1. REMOVE DOOR INSIDE HANDLE BEZEL
a. Open the cap, then remove the screw.
b. Using a screwdriver, remove the inside handle bezel.
HINT: Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
Using a screwdriver, remove the panel as shown in the illustration.
HINT: Tape the screwdriver tip before use.
3. REMOVE DOOR TRIM
a. Using a screwdriver, remove the courtesy light, then disconnect the connector.
HINT: Tape the screwdriver tip before use.
b. Remove the 4 screws and 2 clips.
c. Insert a screwdriver between the trim and door panel to pry the door trim.
HINT: Tape the screwdriver tip before use.
d. Release the claws, then remove the inner weatherstrip from the door trim.
4. REMOVE INSIDE HANDLE
Remove the screw and inside handle, then disconnect the 2 cables.
5. REMOVE SPEAKER
a. Disconnect the connector.
b. Remove the 3 screws and speaker.
6. REMOVE SERVICE HOLE COVER
a. Remove the 2 grommets.
b. Remove the service hole cover.
7. REMOVE DOOR BELT MOULDING
Remove the door belt moulding as shown in the illustration
8. REMOVE LOWER FLAME BRACKET GARNISH
a. Remove the clip.
b. Insert a screwdriver between the lower frame bracket garnish and door panel to pry the garnish out.
HINT: Tape the screwdriver tip before use.
9. REMOVE OUTSIDE REAR VIEW MIRROR
a. Disconnect the connector.
b. Remove the 3 bolts and outside rear view mirror.
10. REMOVE WINDOW GLASS
a. Open the door glass until the bolts appear in the service hole.
b. Remove the 2 bolts and door glass.
NOTE: Do not damage the door glass.
HINT: Pull the glass upward to remove it.
11. REMOVE DOOR GLASS RUN
12. REMOVE WINDOW REGULATOR
CAUTION: When performing the service operation inside the front door on the driver's side, make sure to perform it with the battery terminal or connector of the power window must disconnected.
HINT: If the link or door key lock and unlock switch is touched power window might start its operating, causing unexpected injury to an operator.
As the circuit of the key-linked up-and-down function of the power window is isolated, even if the connector of the power window master switch is disconnected the key-linked up-and-down function operates.
a. Disconnect the connector.
b. Remove the 6 bolts and window regulator.
HINT: Remove the window regulator through the service hole.
13. REMOVE REAR LOWER FRAME
Remove the screw and rear lower frame.
14. REMOVE DOOR LOCK
a. Disconnect the 2 links from the outside handle and key cylinder.
b. Remove the 4 torx screws and door lock.
c. Disconnect the 2 connectors.
HINT: Remove the door lock through the service hole.
d. Remove the 2 screws and door lock cover from the door lock.
15. REMOVE OUTSIDE HANDLE AND KEY CYLINDER
a. Remove the cap, 2 bolts and outside handle with key cylinder.
b. Remove the bolt and key cylinder from the outside handle.
16. REMOVE WEATHERSTRIP
17. REMOVE CUSHIONS
REASSEMBLY
1. INSTALL CUSHIONS
2. INSTALL WEATHERSTRIP
3. INSTALL OUTSIDE HANDLE AND KEY CYLINDER
a. Install key cylinder with the bolt to the outside handle.
b. Install the outside handle with key cylinder to the door panel with the 2 bolts and cap.
4. INSTALL DOOR LOCK
HINT: Apply MP grease to the sliding surface of the door lock.
a. Install the door lock cover with the 2 screws to the door lock.
b. Put the door lock in the service hole.
c. Connect the 2 connectors.
d. Install the door lock with the 4 torx screws.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
HINT: Apply adhesive to the 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent.
e. Connect the 2 links to the outside handle and key cylinder.
5. INSTALL REAR LOWER FRAME
Install rear lower frame with the screw.
6. INSTALL WINDOW REGULATOR
HINT: Apply MP grease to the sliding and rotating parts of the window regulator.
a. Install the window regulator with the 6 bolts, through the service hole.
Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)
b. Connect the connector.
7. INSTALL DOOR GLASS RUN
8. INSTALL WINDOW GLASS
NOTE: Do not damage the door glass.
a. Put the door glass in the door panel carefully.
b. Install door glass with the 2 bolts to the window regulator.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
9. INSTALL OUTSIDE REAR VIEW MIRROR
a. Install the outside rear view mirror with the 3 bolts.
b. Connect the connector.
10. INSTALL LOWER FRAME BRACKET GARNISH
a. Using a heat light, heat the door panel mounting surface to 40 - 60 °C (104 - 140 °F).
NOTE: Do not heat the body excessively.
b. Remove the adhesive tape from the door panel.
c. Wipe off stains with cleaner.
d. If reusing the lower frame bracket garnish:
Clean the lower frame bracket garnish.
1. Using a heat light, heat the lower frame bracket garnish to 20 - 30 °C (68 - 86 °F).
NOTE: Do not heat the lower frame bracket garnish excessively.
2. Remove the adhesive tape from the garnish.
3. Wipe off stains with cleaner.
4. Apply new adhesive tape to the lower frame bracket garnish as shown in the illustration.
Tape Width: 5.0 mm (0.20 in.)
e. Using a brush, coat the contact surface on the door panel with Primer M.
NOTE:
- Let the primer coating dry for 3 minutes or more.
- Do not coat to the adhesive.
- Do not keep any of the opened Primer M for later use.
f. Using a heat light, heat the door panel and garnish.
Door Panel: 40 - 60 °C (104 - 140 °F)
Garnish: 20 - 30 °C (68 - 86 °F)
NOTE: Do not heat the garnish excessively.
g. Lift the adhesive tape release sheet from the face of garnish.
NOTE: When the adhesive tape release sheet is removed, make sure that no dirt or dust can get onto the uncoated area.
h. Push the garnish to the door panel as shown in the illustration.
NOTE: Make sure that the garnish and door panel are heated to the proper temperature.
i. Install the clip.
11. INSTALL DOOR BELT MOULDING
Install the door belt moulding as shown in the illustration.
12. INSTALL SERVICE HOLE COVER
a. Install the service hole cover to the door panel.
b. Install the 2 grommets.
HINT: When installing the service hole cover, pull out the cables and connectors through the service hole cover.
13. INSTALL SPEAKER
a. Install the speaker with the 3 screws.
b. Connect the connector.
14. INSTALL INSIDE HANDLE
Connect the 2 cables, then install the inside handle with the screw.
HINT:
- Check that the door lock knob moves securely to the LOCK and UNLOCK positions when moving the door lock knob.
- When the knob doesn't move to the LOCK and UNLOCK stop positions, move the locking cable installation position back and forth to adjust it.
15. INSTALL DOOR TRIM
a. Install the inner weatherstrip to the door trim.
b. Install the door trim with the 4 screws and 2 clips.
c. Connect the connector, then install the courtesy light to the door trim.
16. INSTALL POWER WINDOW SWITCH
17. INSTALL DOOR INSIDE HANDLE BEZEL
Install the door inside handle bezel with the screw