Front Door: Service and Repair

DISASSEMBLY OF FRONT DOOR

1. REMOVE DOOR INSIDE HANDLE
(a) Remove the screw, and slide the handle forward.
(b) Disconnect the handle from the control link and remove the handle.

2. REMOVE REAR VIEW MIRROR
(a) Using a screwdriver, pry loose the clip and remove the cover.

HINT: Tape the screwdriver tip before use.

(b) Remove the No.3 noise control plate.

(a) Using a screwdriver, remove the power window master switch.

HINT: Tape the screwdriver tip before use.

(b) Disconnect the connector.

(e) Install a screwdriver between the retainers and door trim to pry it loose.

HINT: Tape the screwdriver tip before use.

(f) Disconnect the connector.
(g) Remove the two screws and the speaker.

4. REMOVE SERVICE HOLE COVER
(a) Using a clip remover, remove the screw grommet.
(b) Remove the service hole cover.

5. REMOVE OPENING CONTROL LINK AND INSIDE LOCKING LINK
Disconnect the opening control link and inside locking link from the door lock.

6. REMOVE WEATHERSTRIP
(a) Remove two screws and two clips.
(b) Using a clip remover, remove the nineteen clips.

7. REMOVE FRONT DOOR BELT MOULDING
(a) Wind the glass down into the door cavity.
(b) Remove the screw.
(c) Pry loose the edge of the panel and remove the front door belt moulding.

8. REMOVE DOOR GLASS

(a) Remove two bolts and front door trim supports.
(b) Remove two bolts and door glass stoppers.

9. REMOVE DOOR MIRROR BRACKET
(a) While holding the stud bolt with the hexagon wrench 3 mm (0.118 in.), remove the nut.
(b) Remove the two bolts.

10. REMOVE WINDOW REGULATOR
(a) Disconnect the connector.

(b) Remove four regulator mounting bolts.
(c) Remove two equalizer arm bracket mounting bolts.

(d) Remove the regulator through the service hole.

11. REMOVE FRONT LOWER GUIDE
(a) Remove the one bolt and three nuts.
(b) Remove the front lower guide.

12. REMOVE REAR LOWER GUIDE
(a) While holding the stud bolt with hexagon wrench 3 mm (0.118 in.), remove the two nuts.
(b) Remove the nut.

13. REMOVE DOOR LOCK
(a) Disconnect the links from the door outside handle and door lock cylinder.
(b) Disconnect the connector.
(c) Remove three screws and the bolt.
(d) Remove the door lock with the door lock motor.

14. REMOVE OUTSIDE DOOR HANDLE
(a) Disconnect the connector from the door lock cylinder and room light retainer switch.

(b) Remove the screw and the room light retainer switch.
(c) Remove the bolt from the door lock cylinder.

(d) Remove the two screws and the outside handle protector.
(e) Remove the outside door handle and door lock cylinder with two bolts.

REPLACEMENT OF GLASS
1. REMOVE FOLLOWING PARTS:
(a) Brackets
(b) Bolts
(c) Stabilizers
(d) Washers
(e) Nuts

2. INSTALL EACH PART TO GLASS

ASSEMBLY OF FRONT DOOR

1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE
(a) Apply MP grease to the sliding surface and gears of the window regulator.

NOTICE: Do not apply MP grease to the spring of the window regulator.

(b) Apply MP grease to the sliding surface of the door lock.

2. INSTALL OUTSIDE DOOR HANDLE AND DOOR LOCK CYLINDER
(a) Install the outside door handle and door lock cylinder with two bolts.

(b) Install the outside handle protector with two screws.

(c) Install the room light retainer switch with the screw.

(d) Install the bolt to the door lock cylinder.

3. INSTALL FOLLOWING LINKAGES:
- Opening control link
- Inside locking link

4. INSTALL REAR LOWER GUIDE
Install the rear glass guide with the lower nut (b) and temporarily tighten two upper nuts (a).

5. INSTALL FRONT LOWER GUIDE
Install the front glass guide with the lower nut (b) and temporarily tighten two upper nuts (a).

6. INSTALL WINDOW REGULATOR
(a) Place the regulator through the service hole.
(b) Temporarily tighten two equalizer arm bracket mounting bolts.
(c) Install four regulator mounting bolts.
(d) Connect the connector to the motor.

7. INSTALL REAR VIEW MIRROR BRACKET
Temporarily tighten the nut and two bolts to the rear view mirror bracket.

8. INSTALL DOOR GLASS
(a) Place the glass in the door cavity.
(b) Install the door glass to the regulator with two glass mounting nuts.

9. INSTALL TWO DOOR TRIM SUPPORTS
Install the door trim supports and temporarily tighten two bolts.

10. INSTALL TWO DOOR GLASS STOPPERS
Install the door glass stoppers and temporarily tighten two bolts.

11. INSTALL FRONT DOOR BELT MOULDING
(a) Install the claw of the clips into the upper panel slit and push the moulding onto the panel.
(b) Install the screw to the moulding.

12. INSTALL DOOR WEATHERSTRIP
(a) Install nineteen clips.
(b) Install two screws and two clips.

13. ADJUST DOOR TRIM SUPPORTS
While pressing the claw of the door trim support to the door inner panel, tighten the bolt.

14. ADJUST DOOR GLASS

(a) (In left/right direction - upper side of glass)
Using a hexagon wrench 3 mm (0.118 in.), adjust the stud bolts (a) of the glass guide.
For example, if you turn both stud bolts clockwise, the upper side of the glass move to the outside.

HINT: Turn both stud bolts of the glass guide an equal amount.

(b) (In forward/rearward direction) Adjust the rear guide (b).
(c) (In vertical direction)
Adjust the door glass stopper (c).
(d) (in lean of forward/rearward direction)
Adjust the equalizer arm bracket mounting bolts (d).

15. TIGHTEN EACH BOLT, NUT OF EACH PART

16. CHECK DOOR GLASS
(a) When you close the door with the glass fully closed, check that the A-A, B- B, C-C sections are the same as the condition shown in the illustration.
(b) When you close the door with the glass fully closed, be careful that the glass is not caught in the weatherstrip.
(c) When you raise up the glass, check that the glass and the roof weatherstrip retainer are parallel and the front and rear door glass stoppers touch at the same time.
(d) When you raise up the glass to the middle, check that the gap of the glass is not big in the door trim support.
(e) Check that the glass moves smoothly.
If the above conditions are not met, readjust the glass.

17. INSTALL SERVICE HOLE COVER
(a) Install the service hole cover with adhesive.
(b) Install the lower edge of the cover into the panel slit.
(c) Seal the panel slit with cotton tape.

NOTICE: Do not block the trim clip seating holes with the tape.

(d) Install two screw grommets.

18. INSTALL REAR VIEW MIRROR
(a) Install the rear view mirror with three screws.
(b) Install the No.3 noise control plate to the cover

HINT: If installing the new plate, peel off the backing paper on the plate.

(c) Connect the connector.

19. INSTALL DOOR TRIM
(a) Connect the connector.
(b) Install the door trim with clips to the inside door panel by tapping.
(c) Install two screws and covers.

20. INSTALL MASTER SWITCH
(a) Connect the connector.
(b) Install the master switch to the door trim.

21. INSTALL INSIDE HANDLE
(a) Connect the handle to the control link.
(b) Slide the handle rearward and install the screw.