Reassembly

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ENGINE HOOD / DOOR: FRONT DOOR: REASSEMBLY

REASSEMBLY

1. REPAIR INSTRUCTION
2. INSTALL INNER REAR BLACK OUT FRONT DOOR TAPE
3. INSTALL INNER UPPER BLACK OUT FRONT DOOR TAPE
4. INSTALL NO. 1 BLACK OUT TAPE
5. INSTALL FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY Installation
6. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 8 clips and claw, and install the front door weatherstrip.
7. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
8. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

(a) Engage the 2 guides and install the front door No. 2 stiffener cushion with the 2 bolts.
9. INSTALL DOOR FRAME GARNISH

(a) Engage a new clip and install the door frame garnish.
10. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 17 clips and install the front door weatherstrip.
11. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Install the front door check assembly with the bolt and 2 nuts.
Bolt - Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
Nut - Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
12. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System)

(a) Install the door electrical key oscillator with the screw.
13. INSTALL FRONT DOOR LOCK OPEN ROD

(a) Install the front door lock open rod as shown in the illustration.
14. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System)
(a) Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.

(b) Engage the 2 claws to install the front door outside handle frame sub-assembly.
(c) Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
15. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System)
(a) Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.

(b) Engage the 2 claws to install the front door outside handle frame sub-assembly.
(c) Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
(d) Engage the clamp.
(e) Connect the connector.
16. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Install the front door inside locking cable assembly.

(b) Engage the 3 claws.
17. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

(a) Install the front door lock remote control cable assembly.
18. INSTALL FRONT DOOR LOCK ASSEMBLY
NOTICE:
- When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
- Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
- Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion to the connection. This may result in a malfunction of the front door lock assembly.

(a) Apply MP grease to the sliding parts of the front door lock assembly.
(b) Install a new door lock wiring harness seal to the front door lock assembly.

(c) Insert the front door lock open rod to the front door lock assembly.
(d) Make sure that the front door lock open rod is securely connected to the front door lock assembly.
(e) Using a "TORX" socket wrench (T30), install the front door lock assembly with the 3 screws.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
19. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 2 claws to install the front door rear outside handle pad.
20. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the 3 claws to install the front door front outside handle pad.
21. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System)

(a) Insert the front end of the front door outside handle assembly into the front door outside handle frame.
(b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Next, slide the front door outside handle assembly toward the front of the vehicle to install it.
22. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System)

(a) Engage the 2 claws to install the front door outside handle cover to the front door lock cylinder.

(b) Install the front door lock cylinder.
HINT: Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

(c) Using a "TORX" socket wrench (T30), install the front door lock cylinder with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
(d) Install the hole plug.
24. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)

(a) Using a "TORX" socket wrench (T30), install the front door lock cylinder with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
(b) Install the hole plug.
25. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Install the front door rear lower frame sub-assembly with the bolt.
26. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.
27. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY
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 front power window regulator motor sub-assembly with the 3 screws.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
HINT: A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

28. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY
(a) Apply MP grease to the sliding parts of 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) Tighten the 6 bolts in the order shown in the illustration to install the front window regulator.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated in the order of the arrows in the illustration.

(b) Install the front door glass sub-assembly with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)

(c) Install the hole plug.
30. INSTALL FRONT DOOR SERVICE HOLE COVER
(a) Apply butyl tape to the front door panel.
(b) Pass the front door lock remote control cable and rear door inside the locking cable through a new front door service hole cover.

(c) Attach the front door service hole cover according to the reference points on the front door panel.
NOTE: Securely install the front door service hole cover avoiding wrinkles and air bubbles.

(d) Connect each connector.
(e) Engage the 2 clamps.
31. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER Installation
32. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation
33. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Install the front door inner glass weatherstrip.
34. INSTALL FRONT DOOR WIRE (for Driver Side)

(a) Engage the 3 clamps and install the front door wire.
35. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Engage the 2 claws.
(b) Install the 2 screws and install the front door inside handle sub-assembly.
36. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY
(a) Connect the connector.

(b) Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle sub-assembly.
(c) Engage the 2 clamps.

(d) Engage the front door trim board with the 5 claws on the front door inner glass weatherstrip.
(e) Engage the 9 clips.

(f) Install the 2 screws [B].
(g) Install the screw [A] and front door trim board to the front door panel.
Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)
37. INSTALL COURTESY LIGHT ASSEMBLY
(a) Connect the connector.

(b) Engage the claw and install the courtesy light assembly.
38. INSTALL ASSIST GRIP COVER

(a) Engage the 4 claws and install the assist grip cover.
39. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)

(a) Install the power window regulator master switch assembly with the 3 screws.
40. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side)

(a) Engage the 2 claws and install the door control switch assembly.
41. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)

(a) Engage the 2 claws and install the power window regulator switch assembly.
42. INSTALL FRONT ARMREST UPPER BASE PANEL
(a) Connect the connector.

(b) Engage the 7 claws and clip and install the front armrest upper base panel.
43. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

(a) Engage the 3 claws and install the front door inside handle bezel plug.
44. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Engage the clip and claw, and install the front door lower frame bracket garnish.
45. CONNECT NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

46. INITIALIZE POWER WINDOW CONTROL SYSTEM (for Driver Side) Initialization