Front Door: Service and Repair

FRONT DOOR

Front Door:

Front Door:

Front Door:

DISASSEMBLY

HINT: 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, disengage the clip and claw, and remove the garnish.

HINT: Tape the screwdriver tip before use.

2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH





a. Using a screwdriver, disengage the 3 claws and remove the bezel.

HINT: Tape the screwdriver tip before use.

3. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY





a. Remove the screw.
b. Using a screwdriver, disengage the clip and claw, and remove the armrest base panel upper together with the switch.

HINT: Tape the screwdriver tip before use.

c. Disconnect the connector.
d. Remove the 3 screws and switch from the armrest base panel upper.
e. Using pliers, remove the 2 pins and armrest.

4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH





a. Remove the 3 screws and back frame plate.





b. Remove the 2 cushion rubbers.
c. Remove the 2 screws and the clip A.
d. Using a screwdriver, disengage the other 9 clips.

HINT: Tape the screwdriver tip before use.

e. Remove the trim board upward.

HINT: In order to prevent the door panel from being damaged, cover the areas indicated by arrow marks in the illustration with protective tape.





f. Disconnect the 2 cables from the inside handle, as shown in the illustration.
g. Using a screwdriver, disengage the 10 hooks and remove the weatherstrip inner.

HINT: Tape the screwdriver tip before use.

h. Remove the 2 screws and inside handle.

5. REMOVE FRONT DOOR SERVICE HOLE COVER LH





a. Remove the screw and reinforcement No. 1.
b. Remove the service hole cover.

NOTICE: Remove the tape remaining on the door side.

6. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH





a. Disconnect the connector.
b. Remove the 3 nuts and mirror.

NOTICE: When the nuts are removed, the mirror assembly may fall and become deformed.

7. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
8. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH
9. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH
10. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH

HINT: Insert a shop rag inside the door panel to prevent the door glass from being scratched.





a. Open the door glass until the bolts appear in the service holes.
b. Remove the 2 bolts holding the door glass to the window regulator.





c. Remove the door glass in the direction indicated by the arrow mark in the illustration.

NOTICE:
- Do not damage the door glass.
- When the bolts are removed, the door glass may fall and become deformed.

d. Remove the glass run.

11. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH





a. Disconnect the window regulator connector.
b. Remove the 6 bolts and window regulator.

NOTICE: When the bolts are removed, the window regulator sub-assembly may fall and become deformed.

HINT: Remove the window regulator through the service hole.

12. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx driver (T25), remove the 3 screws and window regulator motor.

13. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH





a. Remove the bolt and frame.

14. REMOVE FRONT DOOR OUTSIDE HANDLE COVER





a. Remove the hole plug.
b. Using a torx socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.

15. REMOVE FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH





a. Disconnect the door lock connector.
b. Using a torx socket wrench (T30), remove the 3 screws and lock.

HINT: Remove the door lock through the service hole.

16. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH





a. Pushing and pulling the outside handle in the direction indicated by the arrow mark in the illustration, remove the outside handle.
b. Remove the outside handle pads front and rear.

17. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH





a. Using a torx socket wrench (T30), loosen the screw.
b. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration, and remove it.

HINT: Remove the outside handle frame through the service hole.

c. Remove the open rod from the outside handle frame.

18. REMOVE FRONT DOOR CHECK ASSEMBLY LH





a. Remove the 2 nuts, bolt and door check.

19. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clips and remove the weatherstrip.

HINT: If the clips are damaged, replace them with new ones.

20. REMOVE FRONT DOOR WIRE LH
a. Disconnect the wire clips.





b. Remove the 2 bolts and wire.

REASSEMBLY

1. INSTALL FRONT DOOR WIRE LH





a. Install the wire with the 2 bolts.

Torque: Reference
8.0 N.m (82 kgf.cm, 71 in.lbf)

NOTICE: 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 wire.

b. Connect the wire clips.

2. INSTALL FRONT DOOR CHECK ASSEMBLY LH





a. Apply MP grease to the sliding area 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)

HINT: Install the door check so that the rivet head is up.

c. Apply adhesive to the threads of the bolt.

Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

d. Install the door check to the body with the bolt.

Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)

3. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH





a. Install the open rod to the outside handle frame.
b. Slide the outside handle frame in the indicated by the arrow mark in the illustration.
c. Using a torx socket wrench (T30), install the outside handle frame with the screw.

Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)

NOTICE: Insert a cover between the nut and the door panel.

d. Install the outside handle pads front and rear.

4. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH





a. Install the outside handle by pushing in the direction indicated by the arrow mark in the illustration.

NOTICE: If the release plate is not pulled and held when installing the outside handle, it will strike against with the outside handle and become damaged.

5. INSTALL FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and area of the door lock.
b. Install a new door lock wire harness packing to the door lock.

NOTICE:
- When reusing a door lock that has been removed, replace the packing in the connecting part with new packing.
- Be careful that no grease or dirt sticks to the packing surface in the connecting part.
- Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.





c. Insert the open rod into the lock and then set it to the door panel.

NOTICE: Make sure that the outside handle link is securely engaged with the door lock.





d. Apply adhesive to the threads of the screws.

Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

e. Using a torx socket wrench (T30), install the lock with the 3 screws.

Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)

f. Connect the lock connector.

6. INSTALL FRONT DOOR OUTSIDE HANDLE COVER





a. Using a torx socket wrench (T30), install the outside handle cover with the screw.

Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)

b. Install the hole plug.

7. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH





a. Install the frame with the bolt.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

8. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx driver (T25), install the regulator motor with the 3 screws.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

HINT: Never rotate the motor assembly counterclockwise until the window glass installation is done.

9. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH





a. Apply MP grease to the sliding and rotating parts of the window regulator.

NOTICE: Do not apply grease to the spring of the window regulator.





b. Install the window regulator with 6 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

c. Connect the window regulator connector.

NOTICE: Be careful not to drop the door window regulator as this may cause deformation.

10. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

NOTICE: Do not damage the door glass.





a. Install the glass run.
b. Insert the door glass into the door panel along the glass run in the direction indicated by the arrow mark in the illustration.





c. Install the door glass to the window regulator with the 2 bolts.

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

d. Reset the power window motor.
e. Inspect operation of the power window.

HINT: When the installation point of the door glass does not match, adjust the regulator position in 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 manual operation.

11. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH





a. Install the mirror with the 3 nuts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

b. Connect the mirror connector.

12. INSTALL FRONT DOOR SERVICE HOLE COVER LH





a. Apply butyl tape to the door panel, as shown in the illustration.
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, confirm the sealing condition.

For Power Window Initialization/Reset Programming and Relearning