Front Door: Service and Repair

Front Door Assembly Removal And Installation

Front Door Assembly Components:

Removal

1. Remove front fender referring to Front Fender Components.
2. Disconnect door harness lead wires at each coupler.
3. Remove door open stopper (1).







4. Support door panel (1) using a jack (2) with rags (3) and a piece of wood (4) placed between jack (2) and panel (1) as shown.







5. Remove door assembly (1) by loosening hinge mounting bolts (2).







Installation

Reverse removal procedure to install door assembly noting the following instructions.
- When replacing door, coat replacement door inside with wax for proper anti-corrosion treatment. Refer to Sealant Application Areas.
- Apply sealant to contact face "A" of hinge (1) and apply grease to rotating part "B" of hinge (1).

"A": Sealant 99000-31110 (SUZUKI Bond No.1215)
"B": Grease 99000-25010 (SUZUKI Super Grease A)

- Tighten hinge bolt to specified torque.

Tightening torque
Door hinge mounting bolt (body side) (a): 27 N.m (2.7 kg-m, 19.5 lbf-ft)
Door hinge mounting bolt (door side) (b): 23 N.m (2.3 kg-m, 17.0 lbf-ft)







- When door open stopper (1) is installed, make sure punch mark (2) is upward.

Door open stopper installing direction
Left side door: L punch mark is upward
Right side door: R punch mark is upward

- Tighten door open stopper bolt (3) to specified torque.

Tightening torque
Door open stopper bolt (a): 27 N.m (2.7 kg-m, 19.5 lbf-ft)







- Adjust door latch striker position referring to Front Door Lock Assembly Removal and Installation.
- Adjust front door cushion so that door becomes flush with side body.
- After installation, open and close the door to check looseness.