Front Door: Service and Repair
FRONT DOOR ASSEMBLY REMOVAL AND INSTALLATIONReference: Front Door Assembly Components
Front Door Assembly Components:
Removal
1. Remove front fender referring to Front Fender Removal and Installation.
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).
Specified sealant and grease.
"A": Sealant 99000-31110SUZUKI Bond No.1215 ()
"B": Grease 99000-25010SUZUKI Super Grease A ()
^ Tighten hinge bolt to specified torque.
Tightening torque
Door hinge mounting bolt (body side) a: 27 Nm (2.7 kgf-m, 19.5 ft. lbs.)
Door hinge mounting bolt (door side) b: 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
^ When door open stopper (1) is installed, be careful make sure punch mark (2) comes to the top.
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: 21 Nm (2.1 kgf-m, 15.5 ft. lbs.)
^ Adjust door latch striker position referring to Front Door Lock Assembly Removal and Installation.
^ After installation, open and close the door to check looseness.