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Front Door: Service and Repair

DISASSEMBLY




1. REMOVE NO. 2 DOOR INSIDE HANDLE BEZEL
Using a screwdriver, remove the No. 2 door inside handle bezel.

HINT: Tape the screwdriver tip before use.




2. REMOVE ARMREST BASE PANEL ASSEMBLY
a. Using a screwdriver, pry the armrest base panel assembly out.

HINT: Tape the screwdriver tip before use.

b. Disconnect the connector and remove the armrest base panel assembly.
c. Remove the 3 screws and window regulator master switch assembly.
d. Remove the 2 screws and separate the upper and lower armrest base panel.




3. REMOVE COURTESY LIGHT ASSEMBLY
a. Using a screwdriver, pry the courtesy light assembly out.
b. Disconnect the connector and remove the courtesy light assembly.




4. REMOVE DOOR TRIM
a. Remove the 7 screws.




b. Using a screwdriver, disengage the clips, then pull the trim upward to remove it.

HINT: Tape the screwdriver tip before use.

c. Disconnect the connectors.




d. Disconnect the 2 cables from the inside handle and remove the door trim.




5. REMOVE INSIDE DOOR HANDLE
a. Remove the screw.
b. Using a screwdriver, disengage the 2 claws and remove the inside door handle.

HINT: Tape the screwdriver tip before use.

c. Remove the No. 1 illumination light assembly and height adjustable anchor switch from the inside handle bezel.

6. Driver's side:
REMOVE SEAT MEMORY SWITCH
Remove the 2 screws and seat memory switch.

7. REMOVE DUCT AND VENT SEAL
Remove the 3 screws, duct and vent seal.

8. REMOVE DOOR TRIM POCKET ASSEMBLY
Remove the 5 screws and door trim pocket assembly.

9. REMOVE DOOR FRAME GARNISH
Remove the 2 clips and door frame garnish.

10. REMOVE OUTSIDE REAR VIEW MIRROR
a. Disconnect the connector.
b. Remove the 3 bolts and outside rear view mirror.

11. REMOVE DOOR SPEAKER
a. Disconnect the connector.
b. Remove the 3 screws and door speaker.

12. REMOVE DOOR ECU
a. Disconnect the connectors.
b. Remove the 2 screws and door ECU.




13. REMOVE SERVICE HOLE COVER




14. REMOVE DOOR BELT MOULDING
a. Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched.
b. Using a moulding remover, remove the door belt moulding.




15. REMOVE DOOR GLASS RUN
a. Using a drill of less than dia 4 mm (0.16 in.).
b. Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.

NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
- Be careful when undertaking this task as the cut rivet is hot.

c. Even if flange is taken off, continue drilling and push cut remaining fragment withe the drill.
d. Remove the door glass run.

16. 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 pull the glass upward to remove it.

NOTE: Do not damage the door glass.




17. REMOVE WINDOW REGULATOR
a. Disconnect the connector.
b. Remove the 6 bolts.
c. Remove the regulator through the service hole.




18. REMOVE WINDOW REGULATOR MOTOR
a. Place the matchmarks on the window regulator motor bracket and regulator gear.
b. Using a torx wrench, remove the 3 screws and motor.

NOTE: Do not rotate the motor only.




19. REMOVE DOOR WINDOW REAR GUIDE
Remove the 2 bolts and door window rear guide.




20. REMOVE DOOR WINDOW FRONT GUIDE
Remove the 2 bolts and door window front guide.




21. w/o Door closer:
REMOVE DOOR LOCK

a. Disconnect the connector.
b. Disconnect the opening control link from the outside handle frame.
c. Using a torx wrench, remove the 3 screws and door lock through the service hole.
d. Remove the door lock remote control cable and door inside locking cable.




22. w/ Door closer:
REMOVE DOOR CLOSER

a. Disconnect the connector and wire harness clamps.
b. Disconnect the opening control link from the outside handle frame.
c. Using a torx wrench, remove the 4 screws and door closer through the service hole.
d. Remove door lock remote control cable and door inside locking cable.

23. REMOVE OUTSIDE HANDLE COVER, OUTSIDE HANDLE AND OUTSIDE HANDLE FRAME
a. Remove the hole plug.




b. Using a torx wrench, loosen the screw and remove the outside handle cover.
c. Remove the outside handle rear pad.




d. Hold the outside handle frame with your hand, and slide the outside handle rearward to remove it.

NOTE: Do not damage the body surface.

e. Remove the outside handle front pad.




f. Remove the nut and outside handle frame.

24. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP
Remove the clip and front door No. 2 weatherstrip.




25. REMOVE WINDOW FRAME FRONT MOULDING
a. Using a drill of less than dia 4 mm (0.16 in.).
b. Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.

NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
- Be careful when undertaking this task as the cut rivet is hot.

c. Even if flange is taken off, continue drilling and push cut remaining fragment with the drill.
d. Remove the moulding.




26. REMOVE WINDOW FRAME REAR MOULDING
Remove the 3 screws and window frame rear moulding.

REASSEMBLY




1. INSTALL WINDOW FRAME REAR MOULDING
Install the window frame rear moulding with the 3 screws.




2. INSTALL WINDOW FRAME FRONT MOULDING
Using an air riveter with nose piece No. 1 install 6 new rivets and moulding.

NOTE:




- Prizing a riveter leads to damage to the riveter, loose tightening and bending the mandrel.




- Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the material.




- Loose tightening also occurs when a rivet is applied between materials without touching.

3. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP
Install the front door No. 2 weatherstrip with clip.




4. INSTALL OUTSIDE HANDLE COVER, OUTSIDE HANDLE AND OUTSIDE HANDLE FRAME
a. Install the outside handle frame with the nut.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

b. Install the outside handle front pad.




c. Hold the outside handle frame with your hand, and slide the outside handle forward to install it.

NOTE: Do not damage the body surface.

d. Install the outside handle rear pad.




e. Using a torx wrench, tighten the screw and install the outside handle cover.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

f. Install the hole plug.




5. w/o Door closer:
INSTALL DOOR LOCK

HINT: Apply MP grease to the sliding and rotating parts of the door lock.

a. Install the door lock remote control cable and door inside locking cable.




b. Using a torx wrench, install the 3 screws and door lock.

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. Connect the opening control link to the outside handle frame.
d. Connect the connector.




6. w/ Door closer:
INSTALL DOOR CLOSER

HINT: Apply MP grease to the sliding and rotating parts of the door closer.

a. Install the door lock remote control cable and door inside locking cable.




b. Using a torx wrench, install the 4 screws and door closer.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

HINT: Apply adhesive to the 4 torx screws.

Part No. 08833-00070, THREE BOND 1324 or equivalent

c. Connect the opening control link to the outside handle frame.
d. Connect the connector and wire harness clamps.




7. INSTALL DOOR WINDOW FRONT GUIDE
Install the door window front guide with the 2 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)




8. INSTALL DOOR WINDOW REAR GUIDE
Install the door window rear guide with the 2 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

9. INSTALL WINDOW REGULATOR MOTOR

NOTE: If having rotated the motor only, reset the motor.

HINT: Never rotate the motor to the down direction until the complete of the window glass installation.




a. Align the matchmarks on the window regulator motor bracket and regulator gear.
b. Using a torx wrench, install the 3 screws and motor.




10. INSTALL WINDOW REGULATOR

HINT: Apply MP grease to the sliding and rotating parts of the window regulator.




a. Install the regulator through the service hole with the 6 bolts.

Torque: 11 N.m (115 kgf.cm, 8 ft.lbf)

b. Connect the connector.




11. INSTALL DOOR GLASS

HINT: Insert a shop rag inside the door panel to prevent scratching the glass.

a. Put the door glass in the door panel carefully.

NOTE: Do not damage the door glass.

b. Install the door glass to the window regulator with the 2 bolts.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)




12. INSTALL DOOR GLASS RUN
Using an air riveter with nose piece No. 1, install 5 new rivets and glass run.












NOTE:
- Prizing a riveter leads to damage to the riveter, loose tightening and bending the mandrel.
- Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the material.
- Loose tightening also occurs when a rivet is applied between materials without touching.




13. INSTALL DOOR BELT MOULDING
Install the door belt moulding as shown in the illustration.




14. INSTALL SERVICE HOLE COVER
15. INSTALL DOOR ECU
a. Install the door ECU with the 2 screws.
b. Connect the connectors.

16. INSTALL DOOR SPEAKER
a. Install the door speaker with the 3 screws.
b. Connect the connector.

17. INSTALL OUTSIDE REAR VIEW MIRROR
a. Install the outside rear view mirror with the 3 bolts.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

b. Connect the connector.

18. INSTALL DOOR FRAME GARNISH
Install the door frame garnish with the 2 clips.

19. INSTALL DOOR TRIM POCKET ASSEMBLY
Install the door trim pocket assembly with the 5 screws.

20. INSTALL DUCT AND VENT SEAL
a. Install the vent seal.
b. Install the duct with the 3 screws.

21. Driver's side:
INSTALL SEAT MEMORY SWITCH
Install the seat memory switch with the 2 screws.

22. INSTALL INSIDE DOOR HANDLE
a. Install the No. 1 illumination light assembly and height adjustable anchor switch to the inside handle bezel.
b. Engage the 2 claws and install the inside door handle.
c. Install the screw.




23. INSTALL DOOR TRIM
a. Connect the 2 cables to the inside handle of the door trim.
b. Connect the connectors.




c. Install the door trim.




d. Install the 7 screws.

24. INSTALL COURTESY LIGHT ASSEMBLY
25. INSTALL ARMREST BASE PANEL ASSEMBLY
a. Assemble the upper and lower armrest base panel with the 2 screws.
b. Install the window regulator master switch assembly with the 3 screws.




c. Connect the connector and install the armrest base panel assembly.

26. INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL

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