Front Door: Service and Repair

Front Door Part 1:

Front Door Part 2:

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 claw, and remove the garnish.

HINT: Tape the screwdriver tip before use.




2. REMOVE DOOR PULL HANDLE
a. Remove the screw and handle upward.




3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
a. Using a screwdriver, disengage the clip and claw, and remove the armrest base panel upper 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.




4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the screw and clip A as shown in the illustration.
b. Using a screwdriver, disengage the 7 clips.

HINT: Tape the screwdriver tip before use.

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 the arrow marks in the illustration.

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

HINT: Tape the screwdriver tip before use.




5. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH
a. Using a screwdriver, disengage the 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 cable from the inside handle.

6. REMOVE FRONT DOOR SERVICE HOLE COVER LH




a. Remove the 2 screws and bracket.




b. Remove the service hole cover.

NOTE: Remove the remaining tape on the door side.




7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Disconnect the mirror connector.
b. Remove the 3 nuts and mirror.

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

8. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH




9. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
a. Using a drill of less than dia 4 mm (0.16 in.), drill out the head of the 3 rivet heads 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 white arrow marks in the illustration.

NOTE: Be careful not to damage the glass.

d. Remove the glass run.




e. Using a screwdriver, disengage the claw and remove the door window glass clip in the direction indicated by the white arrow mark in the illustration.

HINT: Tape the screwdriver tip before use.




11. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Remove the 6 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.




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 REAR LOWER LH
a. Remove the bolt and frame.

HINT: Remove the frame through the service hole.

14. REMOVE FRONT DOOR LOCK ASSEMBLY LH




a. Disconnect the snap and outside locking link from the outside handle as indicated by the white arrow marks in the illustration.
b. Disconnect the snap and lock open rod from the outside handle as indicated by the white arrow marks in the illustration.




c. Twist the knob and remove it, as shown in the illustration.
d. Using a screwdriver, disengage the 2 claws and remove the guide.

HINT: Tape the screwdriver tip before use.




e. Remove the bolt.
f. Using a torx socket wrench (T30), remove the 3 screws and door lock.

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

HINT: Remove the door lock through the service hole.

g. Remove the cable from the lock.




h. Remove the 2 screws and actuator.

15. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH




a. Remove the 2 bolts and handle together with the cylinder.

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




b. Unlock the cylinder by turning it in the direction by the white arrow mark in the illustration
c. Remove the cylinder.




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

HINT: Remove the check through the service hole.

17. 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.




18. 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 ft.lbf)

19. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH




a. Install the cylinder to the handle.
b. Lock the cylinder by turning it in the direction indicated by the white arrow mark in the illustration.




c. Install the handle together with the cylinder with the 2 bolts.

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

20. INSTALL FRONT DOOR LOCK ASSEMBLY LH




a. Install the actuator with the 2 screws.




b. Apply MP grease to the sliding and rotating areas of the door lock.




c. Install the bolt.

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

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.




g. Install the lock open rod and outside locking link in the direction indicated by the arrow marks in the illustration.




h. Install the guide.
i. Attach the knob in the direction indicated by the white arrow mark in the illustration.

HINT: After attaching the knob, rotate it 90 degrees in the direction by the arrow marks in the illustration.




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

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




22. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx driver (T25), install the motor with the 3 screws.

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

23. 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. Install the window regulator with the 6 bolts.

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

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

c. Connect the window regulator connector.

24. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH







a. Install the glass clip in the direction indicated by the white arrow mark in the illustration.
b. Install the glass run.

NOTE: Be careful not to damage the glass.




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




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

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

e. Check 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.

25. INSTALL FRONT NO.1 SPEAKER ASSEMBLY




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




26. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Install the mirror with the 3 nuts.

Torque: 10 Nm (102 kgf.cm, 7 ft.lbf)

b. Connect the mirror connector.

27. 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. Install the bracket with the 2 bolts.