Front Door: Service and Repair

FRONT DOOR DISASSEMBLY

1. REMOVE UPPER BRACKET GARNISH
Using a screwdriver, pry loose two clips and remove garnish.

HINT : Tape the screwdriver tip before use.

2. REMOVE ARMREST BASE PANEL
(a) Using the screwdriver, remove the clip.
(b) Pull the panel backward and disconnect the connector.

3. REMOVE DOOR INSIDE HANDLE BEZEL
(a) Using the screwdriver, pry outward where the handle and bezel meet and remove the rear half of the bezel.
(b) With the door handle in open position, pull the bezel out toward the rear.
(c) Disconnect the connector.

4. REMOVE DOOR TRIM
(a) Using the screwdriver, remove the courtesy light, and disconnect the connector.
(b) Remove seven screws and the hook.

(c) Insert the screwdriver between the panel and the trim and remove the clips.

HINT: Do not scratch the panel with the screwdriver.

(d) Remove the trim by pulling all of the trim up.

5. REMOVE DOOR FRAME GARNISH
(a) Twist the garnish toward the vehicle interior and remove the two clips.
(b) Pull the whole garnish upwards.

6. REMOVE DOOR WEATHERSTRIP
While pulling the weatherstrip by hand, remove the seventeen clips using a clip remover.

HINT: Do not pull strongly on the weatherstrip as it may tear.

7. REMOVE OUTSIDE REAR VIEW MIRROR
(a) Remove the screw and the mirror bracket.
(b) Remove three screws and the mirror.
(c) Disconnect the connector.

8. REMOVE SPEAKER ASSEMBLY
(a) Disconnect the connector from speaker assembly, remove the harness clamp using clip remover, remove the screw and then remove the upper speaker.
(b) Disconnect connectors from speaker assembly and remove speaker assembly with four screws.

9. DISCONNECT WIRE HARNESS FROM DOOR PANEL
Using a clip remover, remove the wire harness clamps from five positions on the door panel.

HINT: Do not break the service hole cover.

10. REMOVE SCREW GROMMETS
Using a clip remover, remove two grommets.
11. REMOVE SERVICE HOLE COVER
Remove the cover by pulling at the edge by hand.

HINT: Do not tear the cover.

12. REMOVE DOOR CHECK
(a) Disconnect the check from the body panel. Using a screwdriver, remove the door check cover.

HINT: Tape the screwdriver tip defore use.

(b) Remove two nuts and the check.

13. REMOVE DOOR INSIDE HANDLE
(a) Remove the two screws.
(b) Disconnect the two links from the handle.

14. DISCONNECT OPENING CONTROL LINK AND INSIDE LOCKING LINK
(a) Remove the intermediate clip of the inside locking link.
(b) Remove the clip joining the inside locking link and door lock, and remove the inside locking link.
(c) Pull the opening control link out of the intermediate clip and remove the door lock clip.
(d) Disconnect the opening control link from the door lock.
15. REMOVE LINK SILENCER

16. REMOVE DOOR GLASS GUIDES AND DOOR GLASS
(a) Remove two nuts joining the window regulator and glass.

HINT: Insert a shop rag inside the panel to prevent scratching the glass.

(b) Remove the three screws and pull out the front glass guide.
(c) Remove the four screws and pull out the rear glass guide.
(d) Pull the door glass out of the panel carefully.

17. REMOVE FRONT DOOR BELT MOULDING
(a) Remove the nine screws.
(b) Using the screwdriver, remove the clips.
(c) Using a scraper, remove the double-sided tape from the rear side.

HINT: Tape the scraper tip before use.

18. REMOVE WINDOW REGULATOR
(a) Using a clip remover, disconnect the connector from the panel.
(b) Remove four bolts and the regulator.

19. REMOVE DOOR LOCK
(a) Remove door lock connector from panel and disconnect it from wire harness.
(b) Disconnect the two links from the outside handle and key cylinder.
(c) Disconnect the wire harness from the clamp of the door lock.
(d) Remove three screws and the door lock.

20. REMOVE OUTSIDE HANDLE AND KEY CYLINDER
(a) Disconnect the connector from the key cylinder.
(b) Remove the handle with the two bolts.
(c) Remove the key cylinder bolt, turn the whole cylinder clockwise and remove it.
21. REMOVE FRONT DOOR OUTSIDE MOULDING

Side Protective Moulding
COMPONENTS

HINT: The clips are located as shown. When using the moulding remover, insert it as close as possible to the moulding clips or retainers.

Front Door Outside Moulding Removal
(a) Pull the lower moulding off with your fingers.
(b) Using a screwdriver, remove the three clips.

HINT: Tape the screwdriver tip before use.

(d) Using a moulding remover, pry out the moulding from the lower side.

HINT: When using the moulding remover, insert it as close as possible to the moulding clips or retainers.

(e) Using a moulding remover, pry out the moulding upper side.
(f) If the clip or the retainer remains on body, remove it with a clip remover.
REPLACEMENT OF COMPONENT PARTS
1. IF NECESSARY, REPLACE UPPER AND LOWER MOULDING
(a) Remove the moulding in the same manner as the front fender lower moulding.

(b) Make the metal plate as shown.
A 6.0 mm (0.236 in.)
B 3.5 mm (0.138 in.)
C 6.0 mm (0.236 in.)
D 0.5 mm (0.020 in.)

(c) Insert the plate between the outside moulding and the lower moulding, install the rivet with a hand riveter.
(d) Remove the plate.

3. IF NECESSARY, REPLACE BODY RETAINERS

REPLACEMENT OF DOOR GLASS
1. REMOVE DOOR GLASS PARTS
(a) Using a screwdriver, remove two cushions (A).
(b) While settling the glass retainers (B) with a torx driver, remove the glass guide rollers (C) and (D).
(c) Remove stud bolts (E), washers (F) and nuts (G), then remove the glass plate (H) and the bracket inner filler
(d) Remove the bolt and the up stop.
2. REPLACE DOOR GLASS
3. INSTALL DOOR GLASS PARTS
Install the parts by following removal sequence in reverse.

ASSEMBLY OF FRONT DOOR
1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE
(a) Apply MP grease to the sliding surface and gears of the window regulator.

NOTICE: Do not apply MP grease to the spring of the window regulator.
(b) Apply MP grease to the sliding surface of the door lock.
(c) Apply MP grease to the door glass guide rollers.

(d) Apply MP grease to the inner side of guide rails.

2. INSTALL FRONT DOOR OUTSIDE MOULDING
INSTALLATION
(a) Check that the clips and retainers are installed on the outside moulding.
(b) Align the clips and retainers with the holes of the door panel.
(c) Tap the moulding by hand to install it.
(d) Install the three screws and a nut.
(e) While pulling the lower moulding, install the three clips.

3. INSTALL OUTSIDE HANDLE AND KEY CYLINDER
(a) Insert the key cylinder into the handle, rotate it counterclockwise and tighten the bolt after the cylinder is engaged.
(b) Install the handle with the two bolts.
(c) Connect the connector to the key cylinder.

4. INSTALL DOOR LOCK
(a) Install the door lock with three screws.
(b) Install the two links to the outside handle and key cylinder.
(c) After installing the door lock connector to the wire harness, install the connector unit to the panel.
(d) Connect the wire harness to the clamp of the door lock.
5. INSTALL WINDOW REGULATOR
(a) Install the regulator with four bolts.
(b) Install the connector unit to panel.

6. INSTALL FRONT DOOR BELT MOULDING

HINT: If the adhesive power of the tape is reduced, replace it with new tape.
- If replacing the moulding, peel off the backing paper on the moulding.
(a) Align the clips with the holes of the panel, and tap the moulding on the panel.
(b) Install nine screws.

7. INSTALL DOOR GLASS WITH GLASS GUIDES TEMPORARILY
(a) Insert the glass with rear glass guide inside the door panel, and temporarily tighten the four screws for the guide.

HINT: Insert a shop rag inside the panel to prevent scratching of the glass.

(b) Fit the front glass guide to the glass guide roller and temporarily tighten the three screws.
(c) Temporarily tighten the two nuts for the glass and window regulator.
8. INSTALL DOOR GLASS STOPPERS AND CUSHION
(a) Install the bolt, cushion, plate and nut.
(b) Temporarily install two stoppers with two bolts.

9. ADJUST DOOR GLASS

HINT: Check that there is space between the glass guide and stopper.
(a) Fully raise the glass, and adjust the gap between the glass and the door panel as shown in the drawing.
(b) After adjustment, immobilize the guides, stoppers and two nuts.

HINT:
- Check that the edge of the glass does not come in contact with the bottom part of the weatherstrip when the glass is being raised or lowered.
- Check that the glass moves up and down smoothly and that the weatherstrip does not get caught by the glass.
(c) Raise the glass again and check the installation.

10. INSTALL LINK SILENCER
Install the new silencer in the position shown in the drawing.

HINT: Before installation, peel off the backing paper at the silencer.

(a) Connect the link with the handle.
(b) Install two screws and the inside handle.
(c) Put the lock button of the inside handle in lock p0sition.
(d) Install the intermediate clip to the link.
(e) Insert the link into the silencer.
(f) Put the door lock on lock with the clip and fix in place the locking link passing through the silencer.
(g) Check that lock operation occurs smoothly.

12. INSTALL OPENING CONTROL LINK AND INSIDE HANDLE
(a) Remove the inside handle and connect the link with the handle.
(b) Install two screws and the handle.
(c) Insert the link into the silencer and install the link in the clip.
(d) Connect the link with the door lock.
(e) Install the edge of the silencer to the panel.
(f) Check that opening operation occurs smoothly.

13. INSTALL SERVICE HOLE COVER

HINT: Before installing the service hole cover, peel off the backing paper from the silencer.

(a) Seal the service hole cover with adhesive.
(b) Insert the lower edge of the service hole cover into the panel slit.
(c) Seal the panel slit with cotton tape.

NOTICE: Do not block the trim clip seating with the tape.

14. INSTALL SCREW GROMMETS
Install two grommets as shown.
15. CONNECT WIRE HARNESS TO DOOR PANEL
Install the clamps onto the panel.
16. INSTALL SPEAKER ASSEMBLY
(a) Install the speaker assembly with four screws.
(b) After installing upper speaker with the screw, install the clamps to the panel and install the connectors to the speaker.

17. INSTALL OUTSIDE REAR VIEW MIRROR
(a) Connect the connector.
(b) Install three screws and the mirror, then install the mirror bracket and the screw.

18. INSTALL DOOR WEATHERSTRIP

HINT: If replacing the weatherstrip, peel off the backing paper on the weatherstrip.

(a) Push down on the seventeen clips and install the lower side of the weatherstrip.
(b) Push the upper side of weatherstrip into the door panel edge by your hand to install the weatherstrip.

19. INSTALL DOOR FRAME GARNISH
(a) Insert lower edge of the garnish into the panel.
(b) Tap in the two clips.
(c) Push the garnish into the frame.

20. INSTALL DOOR TRIM
(a) Insert the upper edge of the trim from above, tap the trim by hand and fix it in place with the clips.

HINT: Keep the connector terminal protruding out from the trim as shown in the drawing.

(b) Install seven screws and the hook.
(c) Connect the connector and install the courtesy light in the trim.

21. INSTALL DOOR INSIDE HANDLE BEZEL
(a) With the door handle in open position, insert the bezel toward the front.
(b) Connect the connector.
(c) Push in the bezel to install it.

22. INSTALL ARMREST BASE PANEL
(a) Connect the connector.
(b) Slide the panel forward and tap the panel to install it.
23. INSTALL UPPER BRACKET GARNISH
Align the clips with the panel holes, then push in the garnish to install it.