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Front Door: Service and Repair



Front Door

REMOVAL

1. FRONT DOOR PANEL

1. Disconnect the ground cable from battery and wait for at least 60 seconds before starting work.
2. Remove the trim panel - front door.
3. Remove the outer mirror assembly.
4. Remove the sealing cover - front door.

CAUTION:
- Carefully remove the butyl tape. Excessive force will easily break the cover.
- If the sealing cover - front door gets broken, replace it with a new part.

1. Remove the screw to remove the bracket - door trim front.
2. Carefully remove the butyl tape to remove the sealing cover - front door.







5. Remove the front door speaker assembly.
1. Remove the screws.
2. Disconnect the connector and remove the front speaker assembly.







6. Remove the front door impact sensor assembly.
1. Remove the front door inner pad (a).
2. Remove the nuts and then remove the front door impact sensor assembly.
3. Disconnect the airbag connector and remove the airbag door sensor assembly.







7. Remove the glass assembly - front door and the glass - front door partition.
8. Remove the regulator & motor assembly - front of the front door.
9. Remove the latch and actuator assembly - front.
10. Remove the handle - door outer.
11. Remove the weather strip - front door.

CAUTION: If the weather strip clip is removed with excessive force, the weather strip may be damaged. Be sure to use clip remover to remove.







12. Remove the bolts and nuts, and then detach the checker assembly - front door.







13. Release the claws, and then remove the cover side sill - front INN.

CAUTION: Do not pull with excessive force. Doing so may damage the claws of the cover side sill - front INN.







14. Remove the clips, and remove the cover side sill - front.







15. Disconnect the front door impact sensor harness connector.

CAUTION: Always refer to "CAUTION" of "General Description" in the "AIRBAG SYSTEM" before performing any service that handles the airbag connectors.

16. Disconnect the front door harness connectors.
1. Disconnect the connector of door harness from body harness.







2. Push in the claws to remove the grommet, and pull out the door harness connector.







17. Before removing the panel assembly - front door, make the following preparations.







1. Put a wooden block on a floor jack and place the jack under the panel assembly - front door.
2. Support the panel assembly - front door with the jack to protect it from damage.

CAUTION: Do not excessively lift the panel assembly - front door with the floor jack. The door hinges may be damaged.

18. Remove the door-side bolts for the upper hinge - front door and the lower hinge - front door to remove the panel assembly - front door.

CAUTION: The panel assembly - front door is heavy. When removing and installing it, always work in a team of two or more persons.







19. Remove the door hinge from vehicle.


2. FRONT DOOR HINGE

1. Remove the bolts from the vehicle side to disconnect the checker assembly - front door.







2. Before removing the door hinge, make the following preparations.
1. Put a wooden block on a floor jack and place the jack under the panel assembly - front door.
2. Support the panel assembly - front door with the jack to protect it from damage.

CAUTION: Do not excessively lift the panel assembly - front door with the floor jack. The door hinges may be damaged.







3. Remove the bolts of the upper hinge - front door or the lower hinge - front door.

CAUTION: Do not remove the upper hinge - front door and the lower hinge - front door at the same time.







4. Remove the hinge - front door from the vehicle.

INSTALLATION

1. FRONT DOOR PANEL

1. Put a wooden block on a jack and place the panel assembly - front door on it.







2. Apply grease to the sliding area of door hinges, and install the door hinge to vehicle.
3. Adjust the height by the jack, and temporarily install the panel assembly - front door to the upper hinge -front door and the lower hinge - front door.

NOTE:
- When installing the panel assembly - front door, make sure that a uniform clearance is created around the panel.
- Perform installation while paying attention to the assembly direction of the grommet.

4. Adjust the clearance around the panel assembly - front door.
5. Tighten the bolts and nuts of the door hinge and the checker assembly - front door.

Tightening torque:
Refer to "COMPONENT" of "General Description".[Ref. to FRONT DOOR, COMPONENT, General Description.]

6. Install door internal parts in the reverse order of removal.
7. Connect door harness connector, and install the cover side sill - front.

2. FRONT DOOR HINGE

1. Apply grease to the sliding area of door hinges, and install the door hinge to vehicle.
2. Adjust the height by the jack, and temporarily install the panel assembly - front door to the upper hinge -front door and the lower hinge - front door.

NOTE: When installing the panel assembly - front door, make sure that a uniform clearance is created around the panel.

3. Adjust the clearance around the panel assembly - front door.
4. Tighten the bolts and nuts of the door hinge and the checker assembly - front door.

Tightening torque:
Refer to "COMPONENT" of "General Description". [Ref. to FRONT DOOR, COMPONENT, General Description.]
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