Front Door: Service and Repair

DISASSEMBLY




1. REMOVE FRONT DOOR INSIDE HANDLE BEZEL
a. Remove the screw.
b. Using a screwdriver with its tip taped, disengage the 2 claws A.
c. Pull out the the front door inside handle bezel in the direction indicated by the arrow, disengage the claw B, and remove the front door inside handle bezel.




2. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY
a. Using a screw driver wrapped with the protective tape, disengage the 5 claws and clip.
b. Disconnect the connector and remove the multiplex network master switch assembly.




3. REMOVE DOOR PULL HANDLE
a. Using a screw driver wrapped with the protective tape, disengage the 2 clips and remove the door pull handle.




4. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH
a. Disengage the claw and the clip, and remove the front door lower frame bracket garnish.




5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY
a. Remove the screw and the clip.
b. Disengage the 7 clips and pull up on the front door trim board sub-assembly to remove it.




6. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
a. Remove the bolt.
b. Disengage the 2 claws and separate the front door inside handle sub-assembly.
c. Disconnect the 2 cables and remove the front door inside handle sub-assembly.

7. REMOVE FRONT NO.1 SPEAKER
8. REMOVE FRONT NO.2 SPEAKER
9. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY




10. REMOVE FRONT DOOR SERVICE HOLE COVER
a. Remove the front door service hole cover.

NOTE: Remove the remaining tape on the door side.

11. REMOVE FRONT DOOR GLASS RUN
a. Connect the multiplex network master switch assembly.
b. Fully lower the front door glass sub-assembly.
c. Remove the front door glass run.

12. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY
a. Move the front door glass sub-assembly so that the door glass bolts can be seen.




b. Remove the 2 bolts and front door glass subassembly.

NOTE: After the bolts are removed, the door glass may fall and became deformed.

c. Disconnect the multiplex network master switch assembly.




13. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
a. Disconnect the connector.
b. Loosen the temporary bolt.

NOTE: If the temporary bolt is removed, the front door window regulator may fall and become deformed.

c. Remove the 5 bolts and the front door window regulator sub-assembly and the power window regulator motor assembly front as a unit.
d. Remove the temporary bolt from the regulator.




14. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT
a. Using a "torx" driver (T25), remove the 3 screws and power window regulator motor assembly front.




15. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER
a. Remove the bolt.
b. Pull out the direction indicated by the arrow, remove the front door frame sub-assembly rear lower.




16. REMOVE FRONT DOOR LOCK ASSEMBLY
a. Disconnect the connector.
b. Remove the bolt.
c. Using a "torx" socket wrench (T30), remove the 3 screws.
d. Separate the 2 link rods and remove the front door lock assembly and cables as a unit.




17. REMOVE FRONT DOOR OUTSIDE HANDLE COVER
a. Remove the hole plug.
b. Using a "torx" socket wrench (T30), loosen the screw.

HINT: Loosen but do not remove the screw.




c. Remove the front door outside handle cover as shown in the illustration.




18. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE
a. Remove the front door handle assembly outside as shown in the illustration.




19. REMOVE FRONT DOOR OUTSIDE HANDLE PAD
a. Disengage the 2 claws and remove the front door outside handle pad.




20. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR
a. Disengage the 2 claws and remove the front door outside handle pad rear.




21. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Using a "torx" socket wrench (T30), loosen the screw.

HINT: Loosen but do not remove the screw.




b. Disengage the claw.




c. Disengage the clip and remove the front door outside handle frame sub-assembly.




22. REMOVE FRONT DOOR CHECK ASSEMBLY
a. Remove the 3 bolts and front door check assembly.




23. REMOVE FRONT DOOR WEATHERSTRIP
a. Disengage the 19 clips and remove the front door weatherstrip.

24. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY

REASSEMBLY

1. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
2. INSTALL FRONT DOOR WEATHERSTRIP




3. INSTALL FRONT DOOR CHECK ASSEMBLY
a. Install the front door check assembly with the 3 bolts.

Torque: door side 5.5 N.m (56 kgf.cm, 49 in.lbf)

Torque: body side 27 N.m (275 kgf.cm, 20 ft.lbf)

4. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Apply body grease to the sliding parts on the front door outside handle frame sub-assembly.




b. Engage the clip.




c. Engage the claw.




d. Using a "torx" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.

Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf)

5. INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR
6. INSTALL FRONT DOOR OUTSIDE HANDLE PAD
7. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE




8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER
a. Using a "torx" socket wrench (T30), install the front door outside handle cover with the screw.

Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf)

9. INSTALL FRONT DOOR LOCK ASSEMBLY

NOTE:
- When reusing the removed front door lock assembly, replace the door lock wire harness sealing on the connector with a new one.
- Do not adhere grease or dust to the door lock wire harness sealing surface of the connector.
- Reusing the door lock wire harness sealing and/ or using damaged door lock wire harness sealing may cause water intrusion to the connection, and result in a malfunction of the front door lock assembly.

a. Apply body grease to the sliding parts on the front door lock assembly.




b. Insert the front door outside handle link rods to the front door lock assembly, and set to front door panel.
c. Make sure that the front door outside handle link is securely connected to the front door lock assembly.
d. Using a "torx" socket wrench (T30), install the front door lock assembly with the 3 screws.

Torque: 5.0 N.m (50 kgf.cm, 45 in.lbf)

e. Install the bolt.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

f. Connect the connector.

10. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER
11. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY FRONT

NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.




a. Using a "torx" driver (T25), install the power window regulator motor sub-assembly front with the 3 screws.

HINT: The new front window regulator adopts a self tapping method. The installation position of regulator will be threaded when the self-tapping screw is inserted.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

12. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
a. Apply body grease to the sliding parts on the front door window regulator sub-assembly.




b. Install the temporary bolt to the front door window regulator sub-assembly.
c. Temporarily install the window regulator.
d. Install the front door window regulator sub-assembly with the 6 bolts.

Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)

e. Connect the connector.




13. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY
a. Install the front door glass sub-assembly with the 2 bolts.

Torque: 5.5 N.m (55 kgf.cm, 48 in.lbf)

14. INSTALL FRONT DOOR GLASS RUN




15. INSTALL FRONT DOOR SERVICE HOLE COVER
a. Apply butyl tape to the front door panel, as shown in the illustration.
b. Install a new front door service hole cover.

16. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY
17. INSTALL FRONT NO.2 SPEAKER
18. INSTALL FRONT NO.1 SPEAKER




19. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY
a. Connect the 2 cables.
b. Engage the 2 claws.
c. Install the front door inside handle sub-assembly with the bolt.
Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)

20. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY
21. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
22. INSTALL DOOR PULL HANDLE
23. INSTALL MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY

24. INSTALL FRONT DOOR INSIDE HANDLE BEZEL
a. Install the front door inside handle bezel with the screw and the 3 claws.

Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)

25. POWER WINDOW CONTROL SYSTEM INITIALIZATION Programming and Relearning