Front Door: Service and Repair
OVERHAULHINT
- The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
- On the RH side, use the same procedures as on the LH side.
1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Using a screwdriver, disengage the clip and claw, and remove the lower frame bracket garnish.
HINT: Tape the screwdriver tip before use.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH
a. Using a screwdriver, disengage the 3 claws and remove the inside handle bezel.
HINT: Tape the screwdriver tip before use.
3. REMOVE FRONT ARMREST ASSEMBLY LH
a. Using a screwdriver, disengage the 2 claws and 2 clips, and then remove the armrest assembly from the trim board sub-assembly.
HINT: Tape the screwdriver tip before use.
4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
a. Using a screwdriver, disengage the 2 claws and 2 clips, and then remove the armrest base panel upper together with the master switch assembly.
HINT: Tape the screwdriver tip before use.
b. Disconnect the master switch connector.
c. Remove the 3 screws and the master switch from the armrest base panel upper.
5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the 2 cushion rubbers.
b. Remove the 3 screws and the clip indicated.
c. Using a clip remover, disengage the other 10 clips.
d. Remove the trim board sub-assembly upward.
HINT: In order to prevent the door panel from being damaged, cover the parts indicated by arrow marks in the illustration with tape.
e. Disconnect the 2 speaker connectors.
f. Disconnect the 2 cables from the inside handle, as shown in the illustration.
g. Remove the inner weatherstrip.
h. Remove the No.2 speaker.
i. Remove the stereo component speaker.
j. Remove the 2 screws and the inside handle sub-assembly.
k. Using a screwdriver, disengage the claw and remove the illumination lamp assembly, as shown in the illustration.
HINT: Tape the screwdriver tip before use.
6. REMOVE FRONT DOOR SERVICE HOLE COVER LH
NOTE: Remove the remaining tape on the door side.
7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Disconnect the mirror connector.
b. Remove the 3 nuts and outer rear view mirror assembly.
NOTE: When the nuts are removed, the outer rear view mirror assembly may fall and become deformed.
8. REMOVE FRONT NO.2 SPEAKER ASSEMBLY
9. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH
10. REMOVE FRONT DOOR BELT MOULDING LH
11. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH
HINT: Insert a shop rag inside the door panel to prevent the door glass sub-assembly from being scratched.
a. Open the door glass until the bolts appear in the service holes.
b. Remove the 2 bolts holding the door glass sub-assembly to the window regulator sub-assembly.
c. Remove the door glass sub-assembly, as shown in the illustration.
NOTE:
- Do not damage the door glass sub-assembly.
- When the bolts are removed, the door glass sub-assembly may fall and become deformed.
d. Remove the glass run.
12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Remove the 6 bolts and window regulator sub-assembly.
NOTE: When the bolts are removed, the window regulator sub-assembly may fall and become deformed.
HINT: Remove the window regulator sub-assembly through the service hole.
13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Place matchmarks on the regulator motor gear and regulator gear.
b. Using a torx driver (T25), remove the 3 screws and window regulator motor assembly.
14. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Remove the bolt and frame sub-assembly.
15. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH
a. Remove the hole plug.
b. Using a torx socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.
16. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Disconnect the door lock connector.
b. Using a torx socket wrench (T30), remove the 3 screws and door lock assembly.
HINT: Remove the door lock assembly through the service hole.
17. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Pushing and pulling the outside handle assembly in the direction of the arrow mark as shown in the illustration, remove the outside handle.
b. Remove the outside handle pads front and rear.
18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a torx socket wrench (T30), loosen the screw.
b. Slide the outside handle frame sub-assembly to remove it.
HINT: Remove the outside handle frame sub-assembly through the service hole.
c. Remove the lock open rod from the outside handle frame sub-assembly.
19. REMOVE FRONT DOOR CHECK ASSEMBLY LH
a. Remove the check cover.
b. Remove the 2 nuts, bolt and door check assembly.
20. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clips, and remove the weatherstrip.
HINT: If the clips are damaged, exchange them for new clips.
21. REMOVE FRONT DOOR WIRE LH
a. Disconnect the wire clips.
b. Remove the 2 bolts and door wire.
22. INSTALL FRONT DOOR WIRE LH
a. Install the door wire with the 2 bolts.
Torque (reference): 8.0 Nm (82 kgf.cm, 71 in.lbf)
NOTE: In order to prevent water leakage, be sure that the lip of the rubber grommet does not turn up or is not deformed when installing the door wire.
b. Connect the wire clips.
23. INSTALL FRONT DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding parts of the door check assembly.
b. Install the door check assembly to the door panel with the 2 nuts.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)
HINT: Install the door check assembly so that the rivet head is up.
c. Apply adhesive to the threads of the bolt.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install the door check assembly to the body with the bolt.
Torque: 30 Nm (306 kgf.cm, 22 in.lbf)
e. Install the check cover.
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Install the lock open rod to the outside handle frame sub assembly.
b. Using a torx socket wrench (T30), install the outside handle frame sub-assembly with the screw.
Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)
NOTE: A cover should be inserted between the nut and the door panel.
c. Install the outside handle pads front and rear.
25. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Pushing the outside handle assembly in the direction of the arrow mark as shown in the illustration, install the outside handle assembly.
NOTE:If the release plate is not pulled and held when installing the outside handle assembly, the release plate will interfere with the outside handle assembly. and damage the release plate.
26. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the door lock assembly.
b. If reusing the door lock assembly:
Install a new door lock wire harness packing.
NOTE:
- If reusing a door lock assembly that has been removed, replace the packing in the connecting part with a new one.
- Be careful that no grease and 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 assembly.
c. Insert the door lock open rod into the door lock assembly, and then set it to the door panel.
NOTE: Make sure that the outside handle link is securely engaged with the door lock assembly.
d. Apply adhesive to the threads of the screws.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
e. Using a torx socket wrench (T30), install the door lock assembly with the 3 screws.
Torque: 5.0 Nm (51 kgf.cm, 42 in.lbf)
f. Connect the door lock connector.
27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), install the outside handle cover with the screw.
Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)
b. Install the hole plug.
28. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Install the door frame sub-assembly with the bolt.
Torque: 5.0 Nm (51 kgf.cm, 42 in.lbf)
29. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Align the matchmarks on the regulator motor gear and regulator gear.
b. Using a torx driver (T25), install the regulator motor assembly with the 3 screws.
Torque: 5.4 Nm (55 kgf.cm, 48 in. lbf)
HINT: Never rotate the motor assembly to the down direction until the window glass installation is done.
30. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the window regulator sub-assembly.
NOTE: Do not apply grease to the spring of the window regulator sub-assembly.
b. Install the window regulator sub-assembly with the 6 bolts.
Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)
c. Connect the window regulator connector.
NOTE: Be careful not to drop and deform the door window regulator sub-assembly as this may cause deformation.
31. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
NOTE: Do not damage the door glass sub-assembly.
a. Install the glass run.
b. Insert the door glass sub-assembly into the door panel along the glass run, as shown into the illustration.
c. Install the door glass sub-assembly to the window regulator sub-assembly with the 2 bolts.
Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)
d. Inspect operation of the power window.
HINT: When the installation point of the door glass sub-assembly does not match adjust the regulator position in manual operation.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Repeat UP and DOWN operation several times in manual operation.
32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Install the outer rear view mirror assembly with the 3 nuts.
Torque: 8.0 Nm (82 kgf.cm, 71 In.lbf)
b. Connect the outer mirror connector.
33. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door panel, as shown in the illustration.
Adhesive: Part No.08850-00065, Butyl Tape Set or equivalent
b. Install the service hole cover.
Dimensions:
HINT:
- When installing the service hole cover, pull out the links and connectors through the service hole cover.
- There should be no wrinkles or folds after attaching the service hole cover.
- After attaching the service hole cover, confirm the sealing condition.
For Power Window Initialization/Reset [1][2]Programming and Relearning