Front Door: Service and Repair

Front Door

REMOVAL

1. Disconnect the ground cable from battery.
2. Remove the front door trim.
3. Remove the outer mirror assembly.
4. Remove the front door speaker assembly.
1. Remove the screws.
2. Disconnect the harness connector and remove the front speaker assembly.







5. Remove the front sealing cover.

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

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







6. Remove the door sash and front door glass.
7. Remove the front door regulator and motor.
8. Remove the front door latch assembly.
9. Remove the front outer handle.
10. Remove the front door weather strip.

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.







11. Remove the bolts and nuts to remove the door checker.







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

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







NOTE: To release the claws of the side sill cover INN, the following steps are recommended.
1. Take out the weather strip from under the side sill cover INN.
2. Turn over the floor mat and release the claw (C-C) by accessing from behind the side sill cover INN.

13. Remove the clip, and remove the side sill cover front.







14. Disconnect the connector of door harness from body harness.







15. Before removing the door panel, make the following preparations.







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

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


16. Remove the door-side bolts for upper and lower hinges to remove front door panel.

CAUTION: Door panels are heavy. When removing and installing them, always work in a team of two or more persons.







17. Remove the door hinge from vehicle.

INSTALLATION

1. Remove the fender cover lower from fender panel.
2. Apply grease to the sliding area of door hinges, and install the door hinge to vehicle.
3. Put a wooden block on jack and place the front door on that.







4. Temporarily install the front door to upper hinge and lower hinge after adjusting the height by jack.

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

5. Adjust the clearance around the front door panel.
6. Install the fender cover lower.
7. Tighten the bolts and nuts of door hinges and door checker.

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

8. Install door internal parts in the reverse order of removal.
9. Connect the door harness connector, and install the front pillar lower trim.