Front Door: Service and Repair
DISASSEMBLYHINT: A bolt without a torque specification is shown in the standard bolt chart.
1. REMOVE INSIDE HANDLE BEZEL
a. Using a screwdriver, open the screw cap.
HINT: Tape the screwdriver tip before use.
b. Remove the screw.
c. Using a screwdriver, remove the inside handle bezel as shown in the illustration.
HINT: Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
a. Using a screwdriver, remove the power window switch.
HINT: Tape the screwdriver tip before use.
b. Disconnect the connectors.
3. REMOVE FRONT ARMREST
a. Remove the screw.
b. Using a screwdriver, remove the front armrest as shown in the illustration.
HINT: Tape the screwdriver tip before use.
4. REMOVE LOWER FRAME BRACKET GARNISH
Remove the lower frame bracket garnish.
5. REMOVE DOOR TRIM
a. Using a screwdriver, remove the courtesy light, then disconnect the connector.
HINT: Tape the screwdriver tip before use.
b. Using a screwdriver, disengage the clips, then pull the trim upward to remove it.
HINT: Tape the screwdriver tip before use.
6. REMOVE FRONT NO. 2 SPEAKER
a. Disconnect the 2 connectors.
b. Remove the 2 bolts and front No. 2 speaker.
7. REMOVE OUTSIDE REAR VIEW MIRROR
a. Disconnect the connector.
b. Remove the bolt and outside rear view mirror.
8. REMOVE FRONT NO. 1 SPEAKER
a. Disconnect the connector.
b. Using a drill of less than dia 4 mm (0.16 in.), drill out the rivet heads and remove the speaker.
c. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
- Take care as the cut rivet is hot.
d. Even if a flange is taken off, continue drilling and push out remaining fragments with the drill.
e. Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door.
9. REMOVE INSIDE HANDLE
Remove the screw and inside handle, disconnect the 2 cables from the inside handle.
10. REMOVE SERVICE HOLE COVER
a. Remove the 2 screws and door trim bracket.
b. Remove the service hole cover.
11. REMOVE FRONT DOOR INSIDE PANEL PLATE
Remove the 2 screws and front door inside panel plate.
12. REMOVE NO. 2 SERVICE HOLE COVER
Remove the 2 screws and No. 2 service hole cover.
13. REMOVE FRONT DOOR BELT MOULDING
a. Remove a screw.
b. Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched.
c. Using a moulding remover, remove the front door belt moulding as shown in the illustration.
14. REMOVE DOOR GLASS
HINT: Insert a shop rag inside the door panel to prevent scratching the 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.
15. REMOVE WINDOW REGULATOR
a. Disconnect the connector and disengage the clamps.
b. Remove the 6 bolts and window regulator.
16. REMOVE WINDOW REGULATOR MOTOR
a. Place matchmarks on the window regulator motor bracket and regulator gear.
b. Remove the 3 screws and motor.
17. REMOVE DOOR GLASS RUN
18. REMOVE REAR LOWER FRAME
Remove the bolt and rear lower frame.
19. REMOVE DOOR LOCK
a. Disconnect the 2 links from the outside handle and key cylinder.
b. Remove the bolt and 2 screws.
c. Using a torx socket wrench, remove the 3 torx screws and door lock.
Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
d. Disconnect the connector.
HINT: Remove the door lock through the service hole.
20. REMOVE OUTSIDE HANDLE AND KEY CYLINDER
a. Remove the screw and hole cover.
b. Remove the 2 bolts and outside handle with the key cylinder.
c. Remove the retainer from the outside handle.
d. Remove the bolt, key cylinder and protector from the outside handle.
21. REMOVE CUSHIONS
REASSEMBLY
1. INSTALL OUTER WEATHERSTRIP
2. INSTALL CUSHIONS
3. INSTALL OUTSIDE HANDLE AND KEY CYLINDER
a. Install the key cylinder and protector with the bolt to the outside handle.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
b. Install the retainer to the outside handle.
c. Install the outside handle with the key cylinder to the door panel with the 2 bolts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
d. Install the hole cover with the screw.
4. INSTALL DOOR LOCK
a. Connect the connector.
b. Using a torx socket wrench, install the door lock with the 3 torx screws.
Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
HINT: Apply adhesive to the 3 torx screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
c. Install the bolt and 2 screws.
d. Connect the 2 links to the outside handle and key cylinder.
5. INSTALL REAR LOWER FRAME
Install the rear lower frame with the bolt.
6. INSTALL DOOR GLASS RUN
7. INSTALL WINDOW REGULATOR MOTOR
a. Align the matchmarks on the regulator motor bracket and regulator gear.
b. Install the 3 screws.
NOTE: Driver's side:
If only the motor is rotated, reset the motor.
HINT: Driver's side:
Never rotate the motor to the down direction mention of the window glass until completing the installation.
8. 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.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
b. Connect the connector and attach the clamps.
9. INSTALL DOOR GLASS
NOTE: Do not damage the door glass.
a. Put the door glass in the door panel carefully.
b. Install the door glass with the 2 bolts to the window regulator.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
10. INSTALL FRONT DOOR BELT MOULDING
Install the front door belt moulding with the screw.
11. INSTALL NO. 2 SERVICE HOLE COVER
Install the No. 2 service hole cover with the 2 screws.
12. INSTALL FRONT DOOR INSIDE PANEL PLATE
Install the front door inside panel plate with the 2 screws.
13. INSTALL SERVICE HOLE COVER
a. Install the service hole cover to the door panel.
HINT:
- When installing the service hole cover, pull out the links and the 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, sealing condition should be confirmed.
b. Install the door trim bracket with the 2 screws.
14. INSTALL INSIDE HANDLE
Connect the 2 cables to the inside handle, then install the inside handle with the screw.
NOTE: At the time of locking cable reassembly, please refer to the following items.
- Set the door lock assembly to the LOCK position.
- Hold the lock knob to the LOCK position by hand, and do not pull the cable while connecting the locking cable.
15. INSTALL FRONT NO. 1 SPEAKER
a. Using an air riveter or hand riveter, install the front No. 1 speaker.
NOTE:
- Do not prize a riveter. It could damage the riveter and cause loose fitting and mandrel bend.
- Do not tilt the riveter when fastening the rivet to the material to avoid loose fitting.
- Do not allow gap spacing between the rivet head and the material.
- Do not allow gap spacing between the materials.
b. Connect the connector.
16. INSTALL OUTSIDE REAR VIEW MIRROR
a. Install the outside rear view mirror with the bolt.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
b. Connect the connector.
17. INSTALL FRONT NO. 2 SPEAKER
a. Install the front No. 2 speaker with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
b. Connect the 2 connectors.
18. INSTALL DOOR TRIM
a. Install the door trim to the door panel.
b. Connect the connector, then install the courtesy light.
19. INSTALL LOWER FRAME BRACKET GARNISH
Install the lower frame bracket garnish to the door panel.
20. INSTALL FRONT ARMREST
Install the front armrest with the screw.
21. INSTALL POWER WINDOW SWITCH
a. Connect the connectors.
b. Install the power window switch.
22. INSTALL INSIDE HANDLE BEZEL
a. Install the inside handle bezel with the screw.
b. Close the screw cap.