Front Door: Service and Repair
Front Door:
OVERHAUL
HINT:
- The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
- On the RH side, use the same procedures as on the LH side.
1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Using a screwdriver, remove the lower frame bracket garnish.
HINT: Tape the screwdriver tip before use.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH
a. Using a screwdriver, disengage the 3 claws, and remove the inside handle bezel.
HINT: Tape the screwdriver tip before use.
3. REMOVE FRONT ARMREST ASSEMBLY LH
a. Disengage the claws, and remove the armrest from the trim board.
HINT: Tape the screwdriver tip before use.
4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the 2 cushion rubbers.
b. Remove the 2 screws and clips.
c. Using a clip remover, remove the 11 clips.
d. Remove the trim board upward.
HINT: In order to prevent the door from being damaged, cover the parts indicated by arrow marks in the illustration with tape.
e. Disconnect the 2 cables from the inside handle as shown in the illustration.
f. Remove the inner weatherstrip.
g. Remove the 3 screws and power window master switch.
h. Using a screwdriver, disengage the 4 claws.
HINT: Tape the screwdriver tip before use
i. Remove the power mirror switch, as shown in the illustration.
5. REMOVE FRONT DOOR SERVICE HOLE COVER LH
NOTE: Remove the remaining tape on the door side.
6. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Disconnect the outer rear view mirror connector.
b. Remove the 3 nuts and outer rear view mirror
NOTE: When the nuts are removed, the outer rear view mirror might drop and be deformed.
7. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
8. REMOVE FRONT NO.2 SPEAKER ASSEMBLY
a. Disconnect the speaker connector.
b. Remove the 2 bolts and No.2 speaker.
c. Remove the 2 bolts and speaker mounting No 1 bracket.
9. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH
10. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH
11. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH
HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched.
a. Open the door glass until the bolts appear in the service holes.
b. Remove the 2 bolts and holding the door glass.
c. Remove the door glass, as shown in the illustration.
NOTE:
- Do not damage the door glass.
- When the bolts are removed, the door glass might drop and be deformed.
d. Remove the door glass run.
12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Remove the 6 bolts and window regulator.
NOTE: When the bolts are removed, the window regulator might drop and be deformed.
HINT: Remove the window regulator through the service hole.
13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Place matchmarks on the window regulator motor gear and regulator gear.
b. Using a Torx(R) driver (T25), remove the 3 screws and window regulator motor.
14. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Remove the bolt and frame rear lower.
15. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH
a. Remove the hole plug.
b. Using a Torx(R) socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.
16. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Disconnect the door lock connector.
b. Using a Torx(R) socket wrench (T30), remove the 3 screws and door lock.
HINT: Remove the door lock through the service hole.
c. Remove the door lock wire harness packing.
17. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Pushing and pulling the outside handle in the arrow mark direction in the illustration, remove the outside handle.
b. Remove the outside handle pad front and rear.
18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a Torx(R) socket wrench (T30), loosen the screw.
b. Slide the outside handle frame from to remove it.
HINT: Remove the outside handle frame through the service hole.
19. REMOVE FRONT DOOR CHECK ASSEMBLY LH
a. Remove the 2 nuts, bolt and the door check.
20. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clips and remove the weatherstrip.
HINT: If the clips are damaged, exchange them for new clips.
21. REMOVE FRONT DOOR WIRE LH
a. Disconnect the door wire clips.
b. Remove the 2 bolts and door wire.
22. INSTALL FRONT DOOR WIRE LH
a. Install the door wire with the 2 bolts.
Torque reference: 8.0 N.m (82 kgf.cm, 71 in.lbf)
NOTE: In order to prevent water leakage, be sure that the lip of the rubber grommet does not turn up or is not deformed when installing the door wire.
b. Connect the door wire clips.
23. INSTALL FRONT DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding parts of the door check.
b. Install the door check to the door panel with the 2 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
c. Apply adhesive to the bolt.
Adhesive:
Part No.08833-00070, THREE BOND 1324 or equivalent
d. Install the door check to the body panel with the bolt.
Torque: 30 N.m (306 kgf.cm, 22 in.lbf)
HINT: Install the door check so that rivet head is up.
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a Torx(R) socket wrench (T30), install the outside handle frame with the screw.
Torque: 7.0 N.m (41 kgf.cm, 35 in.lbf)
b. Install the outside handle pad front and rear.
25. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the door lock.
b. Install a new door lock wire harness packing.
NOTE:
- If reusing the door lock that is removed, replace the packing in the connecting part with a new one.
- Be careful that no grease and dirt will stick to the packing surface in the connecting part.
- Reusing the packing that is removed or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock.
c. Insert the outside handle link into the lock with the door motor, and then set it to the door panel.
NOTE: Make sure that the outside handle link is securely engaged with the lock assembly.
d. Apply adhesive to the 3 screws.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
e. Using a Torx(R) socket wrench (T30), install the door lock with the 3 screws.
Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)
f. Connect the door lock connector.
26. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
a. Using a Torx(R) socket wrench (T30), install the outside handle cover with the screw.
Torque: 7.0 N.m (41 kgf.cm, 35 in.lbf)
b. Install the hole plug.
27. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Install the door frame with the bolt.
Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)
28. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Align the matchmarks on the regulator motor gear and regulator gear.
b. Using a Torx(R) driver (T25), install the door regulator motor with the 3 screws.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
HINT: Never rotate the motor to the down direction until the. window glass installation has done.
29. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the window regulator.
NOTE: Do not apply grease to the spring of the window regulator.
b. Install the window regulator with the 6 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
c. Connect the window regulator connector.
NOTE: Be careful not drop and deform the door window regulator.
30. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
NOTE: Do not damage the door glass.
a. Install the glass run.
b. Insert the door glass into the door panel along the glass run, as shown in the illustration.
c. Install the door glass to the window regulator with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
d. Inspect operation of the power window.
HINT: When the installation point of the door glass does not match, adjust the regulator position in the manual operation.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Repeat UP and DOWN operation several times in the manual operation.
31. INSTALL FRONT NO.2 SPEAKER ASSEMBLY
a. Install the No.1 speaker bracket with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
b. Connect the speaker connector.
c. Install the No.2 speaker with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
32. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Install the outer rear view mirror with the 3 nuts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
b. Connect the outer rear view mirror connector.
33. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door, as shown in the illustration.
Adhesive:
Part No.08850-00065, Butyl Tape Set or equivalent
b. Install the service hole cover.
HINT:
- When installing the service hole cover, pull out the links and connectors through the service hole cover.
- There should be no wrinkles or folds after attaching the service hole cover.
- After attaching the service hole cover, check the sealing condition.