Front Side Door Replacement

Front Side Door Replacement

Special Tools
* J 36346 /KM-327 Fascia Retainer Remover
* KM-298 Remover

Removal Procedure




Warning: Refer to Express Down Feature Warning (Service Precautions).

1. Remove the door check link (3) from the A-pillar.
Remove the bolt.
2. Disconnect the door wiring harness plug (2).

* Disengage the safety clip.
* Disengage the bayonet closure.

3. Remove the door hinge plugs.
Remove the 2 plugs with J 36346 /KM-327.

Note: Protect the edges of the front door with adhesive tape to avoid damaging the paint.

4. Remove the door.
Remove the 2 door hinge tension sleeves (1) with KM-298 .

Installation Procedure

Note: Observe the protective wax corrosion protection measures.

1. When replacing the front door, transfer the attaching parts.
2. Install the door.
Install the 2 door hinge tension sleeves.
3. Install the door hinge plugs.
Install the 4 door hinge plugs.
4. Connect the door wiring harness plug.

* Fasten the bayonet closure.
* Fasten the safety clip.

Caution: Refer to Fastener Caution (Fastener Caution).

Note: Use screw locking compound when inserting the bolt.

5. Install the door check link to the A-pillar and tighten the bolt to 20 Nm (15 lb ft).




6. Adjust the door to fit.

* (I) 4.0+/-1.0 mm (0.16+/-0.04 in)
* (II) 5.0+/-1.0 mm (0.20+/-0.04 in)
* (III) 5.0+/-1.0 mm (0.20+/-0.04 in)
* (IV) 4.1+/-1.0 mm (0.16+/-0.04 in)
* (V) 3.8+/-0.8 mm (0.15+/-0.03 in)
* (VI) 3.8+/-0.8 mm (0.15+/-0.03 in)
* (VII) 3.8+/-0.8 mm (0.15+/-0.03 in)
* (VIII) 4.5+/-1.0 mm (0.18+/-0.04 in)
* (IX) 4.5+/-1.0 mm (0.18+/-0.04 in)
* (X) 3.8+/-0.8 mm (0.15+/-0.03 in)