Removal and Replacement
1. DOOR ASSEMBLY1. Remove lower trim and disconnect connectors from body harness.
2. Place a cloth or a wood block under door to prevent damage, and support it with a jack.
3. Remove checker bolt.
4. Remove bolts (M8) securing upper and lower hinges to door, and remove door from hinges.
Tightening torque:
25 ± 3 N.m (2.5 ± 0.3 kg.m 18.1 ± 2.2 ft.lb)
5. Remove hinges by loosening hinges mounting bolt (M8) off of body.
Tightening torque:
29 ± 5 N.m (3.0 ± 0.5 kg.m, 21.7 ± 3.6 ft.lb)
CAUTION: Work carefully to avoid damaging door.
6. Installation is in the reverse order of removal.
NOTE: Apply grease to moving parts of door hinges.
2. TRIM PANEL
CAUTION: Be careful not to break clip by applying undue force.
1. Front door trim:
1. Remove gusset cover (A), power window switch assembly (B), pocket (C) and inner remote cover (D).
2. Remove screws and then disengage the clips.
3. Detach trim panel and then disconnect connector.
4. Installation is in the reverse order of removal.
2. Rear door trim:
1. Remove handle (E), pocket (F) and clips (G).
2. Remove screws and then disengage the clips.
3. Detach trim panel and then disconnect connector.
4. Installation is in the reverse order of removal.
3. SEALING COVER
1. Remove trim panel.
2. Remove speaker, trim bracket, remote assembly and disconnect connectors.
3. Remove sealer with a spatula.
CAUTION: Be careful because cover may break if sealer is removed forcefully.
4. Installation is in the reverse order of removal.
NOTE:
- Confirm that sealer is properly applied without breaks. Then install sealing cover.
- When repairing or replacing sealing cover, use "CEMEDINE 5430L" as sealer. It may be overlaid on existing sealer.
Sealer: CEMEDINE 5430L
CAUTION:
- Any breaks in sealer can cause water leakage or entry of air and dust. Be sure sealer is applied in a continuous line.
- Make sure sealing cover bonded areas are free from wrinkles or openings.
4. CHECKER
1. Completely close door glass.
2. Remove trim panel.
3. Remove sealing cover.
4. Remove attaching bolt to body.
5. Loosen two nuts securing checker, and take out checker through access hole in underside.
6. Installation should be made in the reverse order of removal.
Tightening torque:
T1: 7.5 ± 2.0 N.m (0.75 ± 0.2 kg.m, 5.4 ± 1.4 ft.lb)
T2: 3.2 ± 10 N.m (3.3 ± 1.0 kg.m, 23.9 ± 7.2 ft.lb)
5. INNER REMOTE
1. Remove trim panel.
2. Remove sealing cover.
3. Disconnect joints of two rods.
4. Unlatch rod holder.
5. Remove inner remote assembly.
6. Installation is in the reverse order of removal
NOTE: It rear door is equipped with child safety lock, check that child lock lever moves without dragging.
6. DOOR LATCH AND OUTER HANDLE
1. Completely close door glass.
2. Remove door trim panel.
3. Remove inner remote assembly.
4. Remove sealing cover around latch service hole.
5. Remove latch and actuator assembly (A):
1. Turn rod holder to disconnect joint between key lock and rod.
2. Turn rod holder to disconnect joint between outer handle and rod.
3. Turn rod holder to disconnect joint between crank and rod.
4. Loosen screws securing both latch and actuator, then remove latch and actuator assembly through service hole in bottom.
5. Installation is in the reverse order of removal.
Tightening torque (screw):
6.4 ± 2.0 N.m (0.65±0.2 kg.m, 4.7 ± 1.4 ft.lb)
NOTE:
- Check operation of each part.
- Check each sliding part for proper lubrication.
CAUTION: After installation, be sure lock mechanism operates normally.
6. Remove outer handle (B):
1. Remove trim panel.
2. Remove sealing cover.
3. Loosen bolts securing outer handle and then remove outer handle from outside.
CAUTION: Be careful not to damage door.
4. Installation is in the reverse order of removal.
Tightening torque:
7.4 ± 20 N.m (0.75 ± 0.2 kg.m 5.4 ± 1.4 ft.lb)
7. KEY LOCK
1. Remove trim panel.
2. Remove sealing cover.
3. Completely close door glass.
4. Remove outer handle.
5. Loosen spring securing key lock.
6. Remove key lock from outer handle.
7. Installation is in the reverse order of removal.
8. GUSSET
1. Be sure window is all the way down.
2. Remove gusset cover.
3. Remove trim panel.
4. Remove door rearview mirror.
5. Remove outer weatherstrip.
6. Remove sealing cover.
NOTE: Be careful not to drop nuts on the "IN" side.
7. Remove bolts and nuts which secure gusset.
Tightening torque: Bolt
13 ± 3 N.m (1.3 ± 0.3 kg.m, 9.4 ± 2.2 ft.lb)
Tightening torque: Nut
7.4 ± 2.0 N.m (0.75 ± 0.2 kg.m 5.4 ± 1.4 ft.lb)
8. Lift out gusset.
9. Installation is in the reverse order of removal.