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Front Door: Service and Repair

Front Door:






FRONT DOOR

OVERHAUL

HINT:
- Installation is in the reverse order of removal. But, the installation is indicated only when it has a point.
- On the RH side, work in the same procedure as in the LH side.

1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY




a. Using a screwdriver, remove the front armrest assembly.

HINT: Tape the screwdriver tip before use.

2. REMOVE DOOR INSIDE HANDLE BEZEL NO.2 LH




a. Using a screwdriver, remove the door inside handle bezel.

HINT: Tape the screwdriver tip before use.

3. REMOVE FRONT DOOR WINDOW UPPER BRACKET GARNISH LH




a. Remove the upper bracket garnish.

4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH




a. Remove the 8 screws.
b. Remove the clip.
c. Using a screwdriver, remove the door panel.

HINT: Tape the screwdriver tip before use.

d. Disconnect the 2 cables from the inside handle.
e. Remove the door trim board.

5. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Disconnect the connector.
b. Remove the 3 bolts and the outer rear view mirror assembly.

6. REMOVE MULTIPLEX NETWORK DOOR ECU FRONT LH
a. Remove the 2 screws and door ECU.

7. REMOVE FRONT DOOR WEATHERSTRIP NO.2
a. Remove the 2 clips and weatherstrip No.2.

8. REMOVE FRONT DOOR GLASS RUN LH
a. Remove the door glass run.




9. REMOVE FRONT DOOR SERVICE HOLE COVER LH
a. Remove the service hole cover.

10. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a screwdriver, remove the door weatherstrip.

HINT: Tape the screwdriver tip before use.

11. REMOVE FRONT DOOR BELT MOULDING LH

12. REMOVE FRONT DOOR SERVICE HOLE COVER NO.2 LH
a. Remove the 4 screws and door service hole cover No.2.




13. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH

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 3 nuts and door glass.

NOTE: Do not damage the door glass.

HINT: Pull the glass upward to remove it.




14. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY LH
a. Disconnect the connector.
b. Remove the 7 nuts and window regulator.




15. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Disconnect the connectors.
b. Disconnect the links from the outside handle.
c. Using a torx socket wrench (T30), remove the 4 torx screws and door lock.

16. APPLICATION BODY GREASE
a. Apply MP grease to the sliding and rotating parts of the regulator assembly and door lock.




17. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a torx socket wrench, remove the screw and door lock key cylinder.
b. Remove the outside handle from the outside handle frame.
c. Remove the nut and front door outside handle frame.

18. REMOVE STEREO COMPONENT SPEAKER ASSEMBLY
a. Remove the 4 screws and speaker.

19. REMOVE FRONT NO.2 SPEAKER ASSEMBLY
a. Remove the 2 screws and front speaker.

20. REMOVE DOOR GLASS FEMALE STABILIZER LH
a. Remove the 2 screws and glass female stabilizer.

21. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Using a torx socket wrench (T30), install the front door lock assembly with the 4 screws.

Torque: 5.5 N.m (56 kgf.cm, 48 in.lbf)

b. Connect the link to the outside handle.
c. Connect the connector.




22. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY LH
a. Install the front door window regulator with the 7 nuts.

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

Lower side:
Torque: 13.0 N.m (133 kgf.cm, 10 ft.lbf)

Motor side:
Torque: 5.5 N.m (56 kgf.cm, 48 in.lbf)

b. Install the power window regulator and door glass.
c. Connect the power window switch to the wire harness and turn the ignition switch ON.
d. Fully close the door glass by a manual operation.
e. By using a round bar (Dia 2 mm) keep the reset switch pressed.
f. Fully open the door glass by a manual operation with the reset switch pressed.
g. Take the round bar away from the reset switch and then fully close the door glass by a manual operation.
h. Check if AUTO UP -> AUTO DOWN operates in the automatic operation.

HINT:
- Note that the jam protection function does not operate just after resetting.
- Reset the regulator again when performing the reverse operation after closing the window fully by AUTO UP operation.

i. Check the power window function.




23. INSPECT FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Check that the clearance is within the standard value.




24. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Fitting adjustment of the front door glass at the upper end in the horizontal direction.
1. Loosen the 2 nuts at the bottom of the window regulator assembly and of the front door mirror bracket.
2. Adjust the fitting of the front door glass at the upper end in the horizontal direction as shown in the illustration, by turning the stud bolt with a hexagon wrench of 2 sides and 4 mm width.

HINT: When the stud bolt is loosened, the upper end of the glass leans to the inside of the vehicle. When the stud bolt is tightened, the upper end leans to the outside.

3. Tighten the 2 nuts.




b. Fitting adjustment at the bottom of the front door glass RH in the horizontal direction.
1. Loosen the 2 nuts
2. Adjust the fitting at the bottom of the front door glass RH in the horizontal direction as shown in the illustration.
3. Tighten the 2 nuts.

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




c. Slant adjustment of the front door glass RH (when fully closed) in the up/down direction and in the front/rear direction.
1. Loosen the installation bolts for the front door glass stopper, and install the glass temporarily in the upper end.
2. Loosen the 3 installation nuts for the front door glass RH.
3. By operating the power window regulator master switch assembly, stop the front door glass RH in approximately 3 mm before the fully-closed position.
4. Adjust the slant of the front door glass RH in the up / down direction and in the front/rear direction as shown in the illustration, holding it up.




5. While holding the front door glass RH in the full-closed position, press it lightly toward the front door glass stopper and then tighten the bolts and nuts properly.

Torque: 11.5 N.m (117 kgf.cm, 8.5 ft.lbf)




25. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Install the service hole cover to the door panel.

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, sealing condition should be confirmed.
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