Front Door: Service and Repair
DISASSEMBLY1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG
a. Using a screwdriver wrapped with protective tape, disengage the 3 claws and remove the front door inside handle bezel plug.
2. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
a. Using a screwdriver wrapped with protective tape, disengage the 2 claws and the 2 clips.
b. Disconnect the connector and remove the power window regulator master switch assembly.
3. REMOVE DOOR ARMREST COVER
a. Remove the door armrest cover.
4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH
a. Using a screwdriver wrapped with protective tape, disengage the 2 clips and claw and remove the front door lower frame bracket garnish.
5. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY
a. Remove the 2 screws.
b. Remove the clip .
c. Pulling the front door trim board sub-assembly in the direction of the arrow shown in the illustration, disengage the 15 clips .
d. Disconnect the cable and each connector from the back side of the inside handle and remove the front door trim board sub- assembly.
e. Disengage the 2 claws and separate the front door courtesy light.
6. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER
a. Remove the front door glass weatherstrip inner as shown in the illustration.
7. REMOVE FRONT DOOR ARMREST SET BRACKET
a. Remove the 2 screws and the front door armrest set bracket.
8. REMOVE FRONT NO.1 SPEAKER
9. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY
10. REMOVE FRONT DOOR SERVICE HOLE COVER
a. Disconnect each connector and remove the front door service hole cover.
HINT: Remove the remaining tape on the door side.
11. REMOVE FRONT DOOR GLASS RUN
a. Connect the power window regulator master switch assembly.
b. Fully lower the front door glass sub-assembly.
c. Remove the front door glass run.
12. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY
a. Move the front door glass sub-assembly so that the door glass bolts can be seen.
b. Remove the 2 bolts.
NOTE: After the bolts are removed, the door glass may fall and become deformed.
c. Remove the front door glass sub-assembly as shown in the illustration.
NOTE: Do not damage the door glass.
d. Disconnect the power window regulator master switch assembly.
13. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
a. Disconnect the connector.
b. Loosen the temporary bolt.
NOTE: If the temporary bolt is removed, the front door window regulator may fall and become deformed.
c. Remove the 5 bolts and the front door window regulator sub-assembly and the power window regulator motor assembly front as a unit.
d. Remove the temporary bolt from the regulator.
14. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT
a. Using a "torx" driver (T25), remove the 3 screws and the power window regulator motor assembly front.
15. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER
a. Remove the bolt and the front door frame subassembly rear lower as shown in the illustration.
16. REMOVE FRONT DOOR LOCK ASSEMBLY
a. Disconnect the connector.
b. Using a "torx" socket wrench (T30), remove the 3 screws.
c. Slide the front door lock assembly downward, pull out the link from the outside handle frame, and remove the front door lock assembly and cables as a unit.
17. REMOVE DOOR LOCK WIRING HARNESS SEAL
18. REMOVE FRONT DOOR OUTSIDE HANDLE COVER
a. Remove the hole plug.
b. Using a "torx" socket wrench (T30), loosen the screw and remove the outside handle cover and the door lock key cylinder as a unit.
HINT: Loosen but do not remove the screw.
19. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE
a. Remove the front door handle assembly outside as shown in the illustration.
20. REMOVE FRONT DOOR OUTSIDE HANDLE PAD
a. Disengage the 3 claws and remove the front door outside handle pad.
21. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR
a. Disengage the 2 claws and remove the front door outside handle pad rear.
22. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Using a "torx" socket wrench (T30), remove the screw.
b. Disengage the claw and remove the front door outside handle frame sub-assembly.
23. REMOVE FRONT DOOR CHECK COVER
a. Disengage the pin and remove the front door check cover as shown in the illustration.
24. REMOVE FRONT DOOR CHECK ASSEMBLY
a. Remove the bolt, 2 nuts, and the front door check assembly.
25. REMOVE FRONT DOOR WEATHERSTRIP
a. Using the clip remover, remove the 3 clips and disengage the 18 clips and remove the front door weatherstrip.
26. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY
27. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR
REASSEMBLY
1. INSTALL FRONT WINDOW FRAME MOULDING REAR
2. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
3. INSTALL FRONT DOOR WEATHERSTRIP
4. INSTALL FRONT DOOR CHECK ASSEMBLY
a. Install the front door check assembly with the bolt and the 2 nuts.
bolt:
Torque: 27 N.m (275 kgf.cm, 20 ft.lbf)
nut:
Torque: 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
a. Apply body grease to the sliding parts on the front door outside handle frame sub-assembly.
b. Install the front door outside handle frame subassembly with the claw.
c. Using a "torx" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.
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
a. Using a "torx" socket wrench (T30), install the front door outside handle cover with the screw.
b. Install the hole plug.
11. INSTALL DOOR LOCK WIRING HARNESS SEAL
12. INSTALL FRONT DOOR LOCK ASSEMBLY
NOTE:
- When reusing the removed front door lock assembly, replace the door lock wire harness sealing on the connector with a new one.
- Do not allow grease or dust to adhere on the door lock wiring harness sealing surface of the connector.
- 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.
a. Apply body grease to the sliding parts on the front door lock assembly.
b. Insert the front door outside handle link to the front door lock assembly, and set it to the front door panel.
c. Make sure that the front door outside handle link is securely connected to the front door lock assembly.
d. 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)
e. Connect the connector.
13. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER
14. INSTALL POWER WINDOW REGULATOR MOTOR SUB-ASSEMBLY FRONT
NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.
a. 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 SUBASSEMBLY
a. Apply body grease to the sliding parts on the front door window regulator sub-assembly.
b. Install the temporary bolt to the front door window regulator sub-assembly.
c. Temporarily install the window regulator.
d. Install the front door window regulator sub-assembly with the 6 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
e. Connect the connector.
16. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
17. INSTALL FRONT DOOR GLASS RUN
18. INSTALL FRONT DOOR SERVICE HOLE COVER
a. Apply butyl tape to the front door panel as shown in the illustration.
b. Install a new service hole cover.
19. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY
20. INSTALL FRONT NO.1 SPEAKER
21. INSTALL FRONT DOOR ARMREST SET BRACKET
22. INSTALL FRONT DOOR GLASS WEATHERSTRIP INNER
23. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY
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 [1][2]Programming and Relearning