Reassembly
DOOR / HATCH: FRONT DOOR: REASSEMBLY
1. INSTALL FRONT DOOR PANEL CUSHION
(a) Engage the 2 claws to install a new front door panel cushion.
2. INSTALL FRONT DOOR BELT MOULDING
3. INSTALL FRONT DOOR NO. 2 WEATHERSTRIP
(a) Engage the 10 clips to install the front door No. 2 weatherstrip.
4. INSTALL FRONT DOOR CHECK ASSEMBLY
(a) Install the front door check assembly with the bolt and 2 nuts.
Bolt - Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
Nut - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
5. INSTALL FRONT DOOR CHECK COVER
(a) Install the front door check cover.
6. INSTALL DOOR ELECTRICAL KEY OSCILLATOR Installation
7. INSTALL FRONT DOOR LOCK OPEN ROD
(a) Install the front door lock open rod as shown in the illustration.
8. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
(a) Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.
(b) Install the front door outside handle frame sub-assembly with the claw.
(c) Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(d) Engage the 2 clamps.
(e) Connect the connector.
9. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY
(a) Install the front door inside locking cable assembly.
(b) Engage the 3 claws.
10. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY
(a) Install the front door lock remote control cable assembly.
11. INSTALL FRONT DOOR LOCK ASSEMBLY
NOTICE:
* When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
* Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
* Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion to the connection. This may result in a malfunction of the front door lock assembly.
(a) Apply MP grease to the sliding parts of the front door lock assembly.
(b) Install a new door lock wiring harness seal to the front door lock assembly.
(c) Insert the front door lock open rod to the front door lock assembly, and set it to the front door outside handle frame.
(d) Make sure that the front door lock open rod is securely connected to the front door lock assembly.
(e) Using a T30 "TORX" socket wrench, install the front door lock assembly with the 3 screws.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
12. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD
(a) Engage the 2 claws to install the front door rear outside handle pad.
13. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD
(a) Engage the 3 claws to install the front door front outside handle pad.
14. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY
(a) Insert the front end of the front door outside handle assembly into the front door outside handle frame.
(b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame then slide the front door outside handle assembly towards the front of the vehicle to install it.
(c) Using a T30 "TORX" socket wrench, install the front door outside handle assembly with the screw.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(d) Connect the connector.
15. INSTALL FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)
(a) Install the front door lock cylinder assembly.
HINT
Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.
(b) Using a T30 "TORX" socket wrench, install the front door lock cylinder assembly with the screw.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(c) Install the hole plug.
16. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)
(a) Engage the 2 claws to install the front door outside handle cover.
17. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
(a) Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(b) Install the hole plug.
18. INSTALL DOOR GLASS FEMALE STABILIZER
(a) Using a T30 "TORX" socket wrench, install the door glass female stabilizer with the 2 screws.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
(b) Install a new plate plug.
19. INSTALL FRONT DOOR WEATHERSTRIP
(a) Engage the 22 clips.
(b) Install the front door weatherstrip with the 4 clips.
20. INSTALL FRONT DOOR DIVISION BAR SEAL
(a) Engage the guide.
(b) Engage the 2 clips and install the front door division bar seal.
21. INSTALL FRONT DOOR FRONT LOWER FRAME UPPER COVER
22. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY
(a) Engage the guide to install the front door glass run to the front door front lower frame sub-assembly.
(b) Install the front door front lower frame sub-assembly with the bolt and nut.
23. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION
(a) Engage the 2 guides and install a new front door No. 2 stiffener cushion with the double-sided tape.
Text in Illustration
(b) Install the 2 bolts.
24. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
(a) Push down on the wire guide and drum, and insert the drum into the power window regulator motor.
NOTICE:
If you cannot insert the drum into the motor, slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.
(b) Engage the guide and 2 claws (A).
(c) Using a water pump pliers, engage the 2 claws (B) and install a new front door power window regulator base plate.
25. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY
(a) Using a 4 mm hexagon wrench, adjust the stud bolts at the bottom of the front door window regulator assembly as shown in the illustration.
Standard Clearance
(b) Apply MP grease to the sliding parts on the front door window regulator assembly.
(c) Temporarily install the front door window regulator assembly with the 7 nuts.
(d) Install the 2 window regulator shims.
(e) Tighten the 7 nuts to install the front door window regulator assembly.
Nut (A) - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
Nut (B) - Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)
Nut (C) - Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
26. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
(a) Connect the cable to the negative (-) battery terminal and the front power window regulator motor connector.
(b) Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass nuts can be seen.
(c) Disconnect the power window regulator master switch assembly and the front power window regulator motor connector.
(d) Disconnect the cable from the negative (-) battery terminal.
(e) Install the front door glass sub-assembly with the 3 nuts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
27. INSTALL FRONT DOOR UPPER WINDOW STOP
(a) for Front Side:
(1) Install the front door upper window stop with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) for Rear Side:
(1) Install the front door upper window stop with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
28. INSPECT FRONT DOOR GLASS SUB-ASSEMBLY
(a) Connect the cable to the negative (-) battery terminal and the front power window regulator motor connector.
(b) Connect the power window regulator master switch assembly and fully close the front door glass sub-assembly.
(c) Disconnect the power window regulator master switch assembly and the front power window regulator motor connector.
(d) Disconnect the cable from the negative (-) battery terminal.
(e) Check that the clearance measurements of areas A through L are within each standard range.
Standard Clearance
NOTICE:
Be careful that each weatherstrip is not cut during door glass adjustment.
29. ADJUST FRONT DOOR GLASS SUB-ASSEMBLY
(a) Adjust the fit of the top part of the front door glass in the inward and outward direction.
(1) Loosen the 2 nuts at the bottom of the front door window regulator assembly.
(2) Using a 4 mm hexagon wrench, turn the stud bolts and adjust the fit of the top part of the front door glass in the inward and outward direction.
HINT
When the stud bolt is turned counterclockwise, the top part of the glass leans toward the inside of the vehicle. When the stud bolt is turned clockwise, the top part of the glass leans toward the outside of the vehicle.
(3) Tighten the 2 nuts after the adjustment.
Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)
(b) Adjust the fit of the bottom part of the front door glass in the inward and outward direction.
(1) Loosen the 2 nuts at the top of the front door window regulator assembly.
(2) Change the number of installed window regulator shims to adjust the fit of the bottom part of the front door glass in the inward and outward direction.
HINT
When more shims are used, the bottom part of the glass moves toward the outside of the vehicle. When less shims are used, the bottom part moves toward the inside of the vehicle.
(3) Tighten the 2 nuts after the adjustment.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(c) Adjust the front door glass fully closed position in the vertical and horizontal directions.
(1) Loosen the bolts of the front door upper window stops and temporarily move the front door upper window stops to the top of their adjustment range and then temporarily retighten the bolts.
(2) Loosen the 3 nuts for the front door glass sub-assembly.
(3) Connect the cable to the negative (-) battery terminal and the front power window regulator motor connector.
(4) Connect the power window regulator master switch assembly and stop the front door glass sub-assembly at approximately 3 mm before the fully closed position.
(5) While holding the front door glass sub-assembly, move it vertically and horizontally to adjust its position.
(6) Tighten the 3 nuts after the adjustment.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(7) Move the front door glass sub-assembly to the fully closed position.
(8) Loosen the bolts for the front door upper window stops.
While lightly pushing each front door upper window stop against the stopper on the front door glass sub-assembly, tighten each bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
Disconnect the power window regulator master switch assembly and the front power window regulator motor connector.
(11) Disconnect the cable from the negative (-) battery terminal.
(12) Install a new plate plug.
30. INSTALL FRONT DOOR SERVICE HOLE COVER
(a) Apply butyl tape to the front door panel.
(b) Pass the front door lock remote control cable and front door inside locking cable through a new front door service hole cover.
(c) Attach the front door service hole cover according to the reference points on the front door panel.
Text in Illustration
NOTICE:
Securely install the front door service hole cover while preventing wrinkles and air bubbles.
(d) Engage each clamp.
(e) Connect each connector.
(f) Connect the wire harness with the bolt.
31. INSTALL DOOR SIDE AIRBAG SENSOR Installation
32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation
33. INSTALL OUTER MIRROR PROTECTOR Installation
34. INSTALL OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory) Installation
35. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation
36. INSTALL FRONT DOOR TRIM COVER
(a) Engage the 6 clips and install the front door trim cover.
37. INSTALL SEAT MEMORY SWITCH (w/ Seat Position Memory System) Installation
38. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
(a) Install the front door inside handle sub-assembly with the 4 screws.
(b) Install the bracket with the 3 screws.
39. INSTALL FRONT NO. 3 SPEAKER ASSEMBLY Installation
40. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY Installation
41. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP
(a) Engage the 8 claws to install the front door inner glass weatherstrip as shown in the illustration.
42. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY
(a) Connect the front door lock remote control cable and front door inside locking cable to the front inside handle.
(b) Connect each connector.
(c) Engage the 10 clips and install the front door trim board sub-assembly to the front door panel.
(d) Install the 2 screws.
43. INSTALL COURTESY LIGHT ASSEMBLY Installation
44. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL
(a) except Wood Panel:
(1) Connect each connector.
(2) Engage the 4 claws and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.
(b) for Wood Panel:
(1) Connect each connector.
(2) Engage the 3 claws and 2 clips to install the power window regulator master switch assembly with front door armrest base panel.
45. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
(a) Engage the 2 clips to install the front door lower frame bracket garnish.
46. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG
(a) Engage the 3 claws to install the front door inside handle bezel plug.
47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
48. INSPECT SRS WARNING LIGHT
Diagnosis System
49. INITIALIZE POWER WINDOW CONTROL SYSTEM
Initialization