Front Door (w/o Power Window)
DISASSEMBLYHINT: Use the same procedures for the RH and LH sides.
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY
a. Pull out the snap ring with a cloth as shown in the illustration, then remove the door window regulator handle assembly.
b. Remove the window regulator handle plate.
3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Disengage the 3 clips and remove the front door lower frame bracket garnish LH.
NOTE: Confirm that no clips remain on the door panel when the garnish is removed. Transfer any remaining clips to the garnish side before installing.
4. REMOVE FRONT DOOR TRIM PANEL ASSEMBLY LH
a. Using a screwdriver with its tip wrapped in protective tape, disengage the 8 claws and remove the door assist grip cover LH.
b. Using a screwdriver with its tip wrapped in protective tape, open the cover.
c. Remove the 3 screws.
d. Disengage the 10 clips and remove the front door trim panel assembly LH.
5. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
6. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY
7. REMOVE FRONT NO. 1 SPEAKER BRACKET
a. Remove the 3 screws and remove the front No. 1 speaker bracket.
8. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH
a. Using a screwdriver with its tip wrapped in protective tape, disengage claw A as shown in the illustration.
b. Move the front door inside handle sub-assembly LH in the direction indicated by the arrow mark in the illustration. This will release the claw and allow the removal of the front door inside handle subassembly LH.
c. Disconnect the 2 cables from the front door inside handle sub-assembly LH.
9. REMOVE FRONT DOOR SERVICE HOLE COVER LH
a. Remove the front door service hole cover LH.
NOTE: Remove the remaining tape on the door side.
10. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
11. REMOVE FRONT DOOR BELT MOULDING LH
12. REMOVE FRONT DOOR INSIDE PANEL PLATE LH
a. Remove the 4 screws and front door inside panel plate LH.
13. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH
HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched.
a. Move the front door glass sub-assembly LH until the 2 bolts appear in the service holes.
b. Remove the 2 bolts.
NOTE: Be careful when removing the 2 bolts as the glass may fall and be damaged.
c. Remove the front door glass sub-assembly LH by moving it in the direction indicated by the arrow marks in the illustration.
NOTE: Be careful not to damage the glass.
14. REMOVE FRONT DOOR GLASS RUN LH
a. Remove the front door glass run LH.
15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Loosen bolt A.
b. Remove the 4 bolts, then remove the front door window regulator sub-assembly LH.
NOTE: Be careful when removing the bolts as the window regulator may fall and be damaged.
HINT: Remove the window regulator through the service hole.
16. REMOVE FRONT DOOR REAR LOWER FRAME SUBASSEMBLY LH
a. Remove the 2 bolts, then remove the front door rear lower frame sub-assembly LH.
17. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH
a. Remove the 2 nuts, then remove the front door front lower frame sub-assembly LH.
18. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH
a. Remove the hole plug.
b. Using a Torx socket wrench T30, loosen the screw and remove the front door outside handle cover LH.
19. REMOVE FRONT DOOR LOCK ASSEMBLY LH
a. Using a Torx socket wrench T30, remove the 3 screws and remove the front door lock assembly LH.
NOTE: Be careful when removing the 3 screws as the door lock may fall and be damaged.
HINT: Remove the door lock through the service hole.
20. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH
a. Remove the front door outside handle assembly LH by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
b. Disengage the 3 claws and remove the front door outside handle front pad.
c. Disengage the 2 claws and remove the front door outside handle rear pad.
21. 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 sub-assembly to remove it.
HINT: Remove the outside handle frame sub-assembly through the service hole.
22. REMOVE FRONT DOOR CHECK ASSEMBLY LH
a. Remove the 2 nuts and bolt, then remove the front door check assembly LH.
23. REMOVE FRONT DOOR WEATHERSTRIP LH (for Regular Cab)
a. Disengage the 36 clips and remove the front door weatherstrip LH.
NOTE: Remove the remaining tape on the door side.
24. REMOVE FRONT DOOR WEATHERSTRIP LH (for Access Cab)
a. Disengage the 36 clips and remove the front door weatherstrip LH.
NOTE: Remove the remaining tape on the door side.
REASSEMBLY
1. INSTALL FRONT DOOR WEATHERSTRIP LH (for Regular Cab)
a. Engage the 36 clips and install a new front door weatherstrip LH.
b. Remove the tab tape at both ends of 2-sided tape attached to the weather strip, and attach the weather strip to the door panel with the 2-sided tape.
2. INSTALL FRONT DOOR WEATHERSTRIP LH (for Access Cab)
a. Engage the 36 clips and install a new front door weatherstrip LH.
b. Remove the tab tape at both ends of 2-sided tape attached to the weather strip, and attach the weather strip to the door panel with the 2-sided tape.
3. INSTALL FRONT DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding areas of the check.
b. Install the front door check assembly LH onto the door panel with the 2 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
c. Apply adhesive to the threads of the bolt.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install the front door check assembly LH onto the body panel with the bolt.
Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
4. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a Torx socket wrench T30, install the outside handle frame sub-assembly with the screw.
Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
NOTE: A cover should be inserted between the nut and the door panel.
5. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY LH
a. Engage the 3 claws and install the front door outside handle front pad.
b. Engage the 2 claws and install the front door outside handle rear pad.
c. Pushing the front door outside handle assembly LH in the direction of the arrow marks shown in the illustration, install the front door outside handle assembly LH.
6. INSTALL FRONT DOOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating parts of the front door lock assembly LH.
NOTE:
- If reusing a door lock assembly that has been removed, replace the packing in the connecting part with new.
- Make sure that no grease and dirt adheres to the packing surface in the connecting part.
b. Insert the door lock open rod into the front door lock assembly, then set it to the door panel.
NOTE: Make sure that the outside handle link is securely engaged with the door lock assembly.
c. Apply adhesive to the threads of the screws.
Adhesive: Part No. 08833-00070 ,THREE BOND 1324 or equivalent
d. Using a Torx socket wrench T30 ,install the front door lock assembly LH with the 3 screws.
Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
7. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
a. Using a Torx socket wrench T30, install the front door outside handle cover LH with the screw.
Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
b. Install the hole plug.
8. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY LH
a. Install the front door front lower frame sub-assembly LH with the 2 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
9. INSTALL FRONT DOOR REAR LOWER FRAME SUBASSEMBLY LH
a. Install the front door rear lower frame sub-assembly LH with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 70 in.lbf)
10. INSTALL FRONT DOOR WINDOW REGULATOR SUBASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the front door window regulator sub-assembly LH.
NOTE: Do not apply grease to the window regulator spring.
b. Loosely screw bolt A onto the front door window regulator sub-assembly LH.
c. Insert the front door window regulator into the door panel. Use bolt A to hang the front door window regulator on the door panel.
NOTE: Be careful not to drop the window regulator as it may be damaged.
d. Install the front door window regulator with the 4 bolts, and tighten bolt A.
Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)
11. INSTALL FRONT DOOR GLASS RUN LH
a. Install the front door glass run LH.
12. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Insert the front door glass sub-assembly LH into the door panel along the glass run as indicated by the arrow marks in the illustration.
b. Install the front door glass sub-assembly LH onto the front door window regulator sub-assembly LH with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
13. INSTALL FRONT DOOR INSIDE PANEL PLATE LH
a. Install the front door inside panel plate LH.
14. INSTALL FRONT DOOR BELT MOULDING LH
15. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
16. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door panel, and install the front door service hole cover LH as shown in the illustration.
Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent
HINT:
- When installing the service hole cover, pull the links and connectors out 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 quality of the seal.
17. INSTALL FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH
a. Connect the 2 cables to the front door inside handle sub-assembly LH.
b. Engage the 3 claws and install the front door inside handle sub-assembly LH onto the door panel.
18. INSTALL FRONT NO. 1 SPEAKER BRACKET
a. Install the front No. 1 speaker bracket with the 3 screws.
b. Connect the wire harness clamp and connector.
19. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY
20. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 N.m (40 kgf.cm, 35 in.lbf)
22. INSTALL FRONT DOOR TRIM PANEL ASSEMBLY LH
a. Engage the 10 clips and install the front door trim panel assembly LH.
b. Install the 3 screws.
c. Engage the 8 claws and install the door assist grip cover LH.
d. Close the cover.
23. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Engage the 3 clips and install the front door lower frame bracket garnish LH.
NOTE: Confirm that no clips remain on the door panel before the garnish is installed. Transfer any remaining clips to the garnish side before installing it. Installing the garnish with any clips remaining on the door panel side could cause the clips to drop inside the door panel.
24. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY
a. Install the window regulator handle plate.
b. Install the front door window regulator handle assembly with the snap ring.