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Front Door: Service and Repair

OVERHAUL

HINT:
- Installation is in the reverse order of removal. But the installation is indicated only when it has a point.
- In 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 power window regulator master switch assembly then disconnect the connector.

HINT: Tape the screwdriver tip before use.




2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Using a screwdriver, remove the front door lower frame bracket garnish.

HINT: Tape the screwdriver tip before use.




3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH
a. Using a screwdriver, remove the front door inside handle bezel plug.

HINT: Tape the screwdriver tip before use.




4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the 2 screw.
b. Using a screwdriver, remove the front door trim board.

HINT: Tape the screwdriver tip before use.

c. Remove the inside handle then disconnect the 2 cables from the front door lock assembly.
d. Disconnect the connector.

5. REMOVE FRONT DOOR SERVICE HOLE COVER LH
a. Disconnect each connector and remove the front door service hole cover.

NOTE: Remove the remained tape on the body side.

6. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
a. Disconnect the connector.
b. Remove the 3 bolt and the front No.1 speaker assembly.




7. 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 2 bolts and door glass.

NOTE: Do not damage the door glass.

HINT: Pull the glass upward to remove it.

8. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the connector.
b. Loosen the temporarily installed bolt.

NOTE: When the temporarily installed bolt is removed, the front door window regulator might drop and be deformed.

c. Remove the 5 bolts and front door window regulator.

9. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx wrench (T25), remove the 3 screws and the motor assembly.

10. REMOVE FRONT DOOR GLASS RUN LH

11. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH
a. Remove the bolt and the front door frame sub-assembly front lower.

12. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Remove the bolt and the front door frame sub-assembly rear lower.




13. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH
a. Remove the hole plug
b. Using a torx wrench (T30), loosen the screw and remove the front door outside handle cover with the door lock key cylinder installed.

14. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Disconnect the connector.
b. Using a torx wrench (T30), remove the 3 screws and the front door w/ motor lock assembly.




15. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Pushing the outside handle in the arrow mark direction in the illustration, remove the front door outside handle.




16. REMOVE DOOR OUTSIDE HANDLE SUB-ASSEMBLY LH
a. Using a torx wrench (T30), loosen the screw.
b. Using pliers, disengage the clips and remove the front door outside handle, as shown in the illustration.

NOTE: Be sure to remove the outside handle together with the clips, because the clips will be damaged if the clips remain attached to the door panel.

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

HINT: Tape the screwdriver tip before use.

18. REMOVE FRONT DOOR WEATHERSTRIP UPPER
a. Using a screwdriver, remove the door weatherstrip No.2.

HINT: Tape the screwdriver tip before use.

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

20. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH

21. INSTALL DOOR OUTSIDE HANDLE SUB-ASSEMBLY LH
a. Using a torx wrench (T30), install the front door outside handle.

22. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Install a new door lock wire harness packing.

NOTE:
- If reusing the removed lock with front door motor, the packing in the connecting part should be replaced with a new one.
- Be careful that grease and dirt will not stick to the packing surface in the connecting part.
- Reusing the removed packing or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock.

b. Insert the outside handle link into the lock assembly with front door motor, and then set it to the door panel.

NOTE: Make sure that the outside handle link is securely engaged with the lock assembly.

c. Using a torx wrench (T30), install the front door lock assembly with the 3 screws.




23. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
a. Using a torx wrench (T30), install the front door outside handle cover with the screw.

24. INSTALL FRONT DOOR GLASS RUN LH
a. Install a new front door glass run to the door panel.

25. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the regulator assembly.
b. If the jam protection does not function properly, perform the following procedure.

HINT: It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed.

1. Remove the power window motor.

HINT: Place the matchmarks on the power window motor and window regulator gear.

2. Connect the power window motor and power window switch to the wire harness of the vehicle.
3. Turn the ignition switch ON and operate the power window switch to idle the power window motor in the up side direction for more than 6 rotations or less than 10 rotations (4 seconds or more).
4. Assemble the power window motor and regulator.

HINT:
- The motor should be installed when the regulator arm is in the middle, not around the upper end (more than 50 mm clearance is necessary from the upper end).
- Align the matchmarks on the power window motor and window regulator gear when installing the power window motor.

5. Assemble the power window regulator and door glass.

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

26. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Install the temporarily installed bolt securely.
b. Install the temporarily installed bolt to the window regulator to the front door panel, and install the front door window regulator temporarily.
c. Tighten the 5 bolts and the temporarily installed bolt.
d. Disconnect the connector.

27. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Install the front door glass with the 2 bolts.

HINT: When the installation point of the front door glass does not match, adjust the regulator position by manual operation.

1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Repeat UP and DOWN operation several times manually.
3. 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 operating after closing the window fully by AUTO UP operation.

28. INSPECT POWER WINDOW FUNCTION




29. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Install a new 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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