Repair Procedures
Replacements
Door Trim Replacement
NOTE:
- Take care not to scratch the door trim and other parts.
- Put on gloves to protect your hands.
1. Remove the quadrant inner cover (A).
2. After loosening the mounting screw, then remove the inside handle cover (A).
3. Loosen the door trim (A) mounting screws.
4. Release the clips that hold the door trim.
5. Disconnect the connectors (A) and (B).
6. Installation is the reverse of removal.
NOTE:
- Make sure of connectors is plugged in properly and each rod is connected securely.
- Make sure the door lock and opens properly.
Inside Handle Replacement
1. Remove the door trim
2. Loosen the mounting screw, then remove the inside handle (A).
3. Disconnect the lock cable (A) and inside handle cable (B).
4. Installation is the reverse of removal.
NOTE:
- Make sure the door locks and opens properly.
Glass Replacement
1. Remove the front door trim.
2. Remove the door screen.
NOTE:
- Using the door switch to align the mounting hole with the hole on the door glass.
- If it is impossible, align the hole by hand after removing the motor.
- Be careful not to drop to glass and scratch the glass surface.
3. Carefully adjust the glass (A) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.
Tightening torque :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7 lb-ft)
4. Installation is the reverse of removal.
NOTE:
- Roll the glass up and down to see if it move freely without binding.
- Adjust glass position as needed.
Speaker Replacement
1. Remove the door trim.
2. Drill out the rivets to remove the speaker (B) from the door module.
3. Disconnect the speaker connector (A).
4. Installation is the reverse of removal.
NOTE:
- Use sheet metal screws to secure the speaker.
Power Window Motor Replacement
1. Remove the door trim.
2. Remove the door screen.
3. After disconnecting the connector (A), remove the power window motor (B).
4. Installation is the reverse of removal.
NOTE:
- Grease should be applied to areas where there is rotational parts and springs.
- Roll the glass up and down to see if it move freely without binding.
Door Module Assembly Replacement
1. Remove the following parts.
A. Door trim
B. Door screen
C. Window glass
D. Outside handle
2. Disconnect the outside handle connector (A).
3. Loosen the mounting bolt (A).
Tightening torque :
0.7 - 0.5N.m (0.07 - 0.1kgf.m, 1.0 - 0.7 lb-ft)
4. Loosen the rear channel mounting nuts.
5. After disconnecting the glass molding, remove the rear channel (A).
6. Disconnect the rod (A).
7. Disconnect the clip (A).
8. Loosen the door module mounting bolts, remove the door module (A).
9. Disconnect the connector.
10. Disconnect the door module wiring harness, remove the module assembly.
Tightening torque :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7 lb-ft)
11. Installation is the reverse of removal.
NOTE:
- The area of whole parts should be applied with sufficient grease.
- Make sure the connector are connected properly and each rod is connected securely.
- Make sure door lock operates and door open/close properly.
Out Side Handle Replacement
1. Remove the door trim.
2. Remove the door screen.
3. Disconnect the outside handle rod (A).
4. Remove the hole plug (B).
5. After loosening the mounting bolt, then remove the outside handle cover (A).
6. Remove the outside handle (A) by sliding it rearward.
7. Disconnect the outside handle connector (A).
8. Installation is the reverse of removal.
NOTE:
- Make sure the door lock and open properly.
Adjustment
Glass Adjustment
NOTE:
- Check the glass run channel for damage or deterioration, and replace them as needed.
1. Remove the following parts:
A. Quadrant inner cover
B. Door trim
C. Door screen
2. Carefully move the glass (A) until the glass mounting bolts are visible, then loosen them.
3. Check that the glass moves smoothly.
4. Raise the glass fully, and check for gaps. Check that the glass contacts the glass run channel evenly.
5. Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items:
A. Use a 12mm (1/2in.) diameter hose (A).
B. Adjust the rate of water flow as shown (B).
C. Do not use a nozzle.
D. Hold the hose about 300mm(12in.) away from the door.
Door Position Adjustment
NOTE:
- After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the mounting bolts.
1. Check that the door and body edges are parallel.
2. Place the vehicle on a firm, level surface when adjusting the doors.
3. Adjust at the hinges (A) :
A. Loosen the door mounting bolts slightly, and move the door in or out until it aligns flush with the body.
B. Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize the gaps.
C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.
Tightening torque :
(B) : 21.6 - 26.5N.m (2.2 - 2.7kgf.m, 15.9 - 19.5 lb-ft)
(C) : 34.3 - 41.2N.m (3.5 - 4.2kgf.m, 25.3 - 30.4 lb-ft)
4. Grease the pivot portions of the hinges indicated.
5. Check for water leaks.
Door Striker Adjustment
Make sure the door latches securely without slamming it. If necessary adjust the striker (A): The striker nuts are fixed. The striker can be fine adjusted up or down, and in or out.
1. Loosen the screws (B), then insert a shop towel between the body and striker.
Tightening torque :
(B) 16.7 - 21.6N.m (1.7 - 2.2kgf.m, 12.3 - 15.9 lb-ft)
2. Tap on the striker with a plastic hammer to adjust the striker. The striker will not move much, but will give some adjustment.
3. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck.