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 front door opening weather-strip.
4. Remove door open stopper (1).







5. 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.







6. 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:Wagon or Sealant Application Areas:Sedan.
- Apply sealant to contact face "A" of hinge (1) and apply grease to rotating part "B" of hinge (1).
Specified sealant and grease.
"A": Sealant 99000 31110
"B": Grease 99000 25010







- When door open stopper (1) is installed, be careful to face side of door open stopper.

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) as specified torque.

Tightening torque
Door open stopper bolt (a): 28 N.m (2.8 kg-m, 20.5 lbf-ft)







- Set weather-strip convex part to door panel notch part securely.







- 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.