Front Door: Service and Repair

Front Door:

OVERHAUL

HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- Use the same procedures for the RH side and LH side.




1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Using a screwdriver, disengage the clip and remove the garnish.

HINT: Tape the screwdriver tip before use.




2. REMOVE FRONT ARMREST BASE PANEL UPPER LH
a. Using a screwdriver, disengage the 12 claws and 2 clips, and remove the armrest base pane together with the switch.

HINT: Tape the screwdriver tip before use.

b. Disconnect the switch connector.
c. Remove the 3 screws and the switch from the armrest base panel upper.




3. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the screw and clip A as shown in the illustration.
b. Using a clip remover, disengage the 7 clips.
c. Remove the trim board upward.

HINT: In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by arrow marks in the illustration.

d. Using a screwdriver, disengage the claws and remove the weatherstrip inner.

HINT: Tape the screwdriver tip before use.




4. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH
a. Using a screwdriver, disengage claw A as shown in the illustration.

HINT: Tape the screwdriver tip before use.

b. Move the inside handle in the direction indicated by the arrow mark in the illustration.
c. Disconnect the 2 cables from the inside handle.

5. REMOVE FRONT DOOR SERVICE HOLE COVER LH




a. Remove the 2 bolts indicated by the arrow marks in the illustration and bracket.




b. Disconnect the 2 connectors.
c. Using a screwdriver, remove the clip indicated by the arrow mark and remove the wire.

HINT: Tape the screwdriver tip before use.

d. Remove the service hole cover.

NOTE: Remove the remaining tape on the door side.

6. REMOVE FRONT NO.2 SPEAKER ASSEMBLY




7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Disconnect the mirror connector.
b. Remove the 2 nuts and mirror.

NOTE: Be careful when removing the nuts as the mirror may fall and become damaged.




9. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
a. Using a drill of less than dia 4 mm (0.16 in.), drill out the heads of the 3 rivets and remove the speaker.

NOTE:
- Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
- Be careful as the cut rivet will very hot.

b. Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
c. Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.

10. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH

HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched.




a. Move the door glass until the bolts appear in the service holes.
b. Remove the 2 bolts holding the door glass to the window regulator.

NOTE: Be careful when removing the bolts as the glass may fall and become damaged.




c. Remove the door glass in the direction indicated by the arrows in the illustration.

NOTE: Be careful not to damage the glass.




d. Using a clip remover, remove the clip as shown in the illustration.
e. Remove the glass run.




11. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Loosen bolt A as shown in the illustration.
c. Remove the 5 bolts and window regulator.

NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.

HINT: Remove the window regulator through the service hole.

d. Remove bolt A from the window regulator.




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




13. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH
a. Remove the bolt and frame.

HINT: Remove the frame through the service hole.




14. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Remove the bolt and frame.

HINT: Remove the frame through the service hole.




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




16. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Using a torx socket wrench (T30), remove the 3 screws and door lock.

NOTE: Be careful when removing the bolts as door lock may fall and become damaged.

HINT: Remove the door lock through the service hole.




17. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
b. Remove the outside handle pad front and rear.

NOTE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.

18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH




a. Using a torx socket wrench (T30), loosen the screw of the frame.




b. Using pliers, remove the clip and handle frame, as shown in the illustration.

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

HINT: Remove the frame through the service hole.




19. REMOVE FRONT DOOR CHECK ASSEMBLY LH
a. Remove the 3 bolts and the door check.

HINT: Remove the check through the service hole.

20. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clips and remove the weatherstrip.

HINT: If clips are damaged during removal, replace them.




21. INSTALL FRONT DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding areas of the check.
b. Install the check to the door panel with the 2 bolts.

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

c. Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

d. Install the check to the body panel with the bolt.

Torque: 30 Nm (306 kgf.cm, 22 in.lbf)




22. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Install the outside handle link.
b. Apply MP grease to the sliding areas of the frame.
c. Using a torx socket wrench (T30), install the frame with the screw.

Torque: 4.0 Nm (41 kgf.cm, 35 in.lbf)




23. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Install the outside handle pad front and rear.
b. Install the handle by pushing it in the direction of the white arrow mark in the illustration.

NOTE: If the release plate is not pulled and held when installing the handle, the release plate will interfere with the handle and become damaged.

24. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the door lock.
b. Install a new door lock wire harness packing.

NOTE:
- When reinstalling a door lock, always use new packing.
- Do not allow grease or dirt to contaminate the gap between the door panel and packing.
- Old packing or damaged packing cannot effectively protect against water. Water will damage the door lock.




c. Insert the control rod into the door lock, and then set it to the door panel.

NOTE: Make sure that the rod is securely engaged with the lock.




d. Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

e. Using a torx socket wrench (T30), install the door lock with the 3 screws.

Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)

f. Connect the door lock connector.




25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), install the cover (with the door lock key cylinder installed) with the screw.

Torque: 4.0 Nm (41 kgf.cm, 37 in.lbf)

b. Install the hole plug.




26. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Install the frame with the bolt.

Torque: 6.2 Nm (63 kgf.cm, 55 in.lbf)




27. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH
a. Install the frame with the bolt.

Torque: 6.2 Nm (63 kgf.cm, 55 in.lbf)




28. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx driver (T25), install the motor with the screws.

Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf)

29. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH




a. Apply MP grease to the sliding and rotating areas of the window regulator.

NOTE: Do not apply grease to the spring of the window regulator.




b. Loosely screw bolt A onto the window regulator.
c. Insert the window regulator into the door panel. Use bolt A to hang the window regulator on the door panel.
d. Install the window regulator with the 5 bolts and tighten bolt A.

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

NOTE: Be careful not to drop the window regulator as it may become damaged.

e. Connect the window regulator connector.

30. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH




a. Install the glass run.

NOTE: Be careful not to damage the glass.

b. Insert the door glass into the door panel along the glass run as indicated in the illustration.




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

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

d. Inspect operation of the power window.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Use the UP and DOWN function several times.

31. INSTALL FRONT NO.1 SPEAKER ASSEMBLY




a. Using a hand riveter or an air riveter, install the speaker to the door with the 3 rivets.

NOTE:




- Do not operate the riveter at an angle as this will damage it and bend the mandrel.




- Do not tilt the riveter when installing the rivet as the speaker will not be tightened firmly.




- Install the rivet while attaching the speaker to ensure that it is tightened firmly.

b. Connect the speaker connector.




32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Install the mirror with the 2 nuts.

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

b. Connect the mirror connector.




33. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door as shown in the illustration.
b. Install a new service hole cover.

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, check the sealing quality.

c. Connect the 2 connectors and install the wire.
d. Install the trim bracket with the 2 bolts.