Disassembly and Reassembly

FRONT DOOR DISASSEMBLY





1. REMOVE DOOR INSIDE HANDLE BEZEL
(a) Using a screwdriver, pry out the bezel.

HINT: Tape the screwdriver tip before use.

(b) Pull the bezel rearwards to remove it.

2. REMOVE DOOR TRIM





(a) Remove the armrest cover.
(b) Remove a cap.
(c) Remove two screws.
(d) Remove two clips.
(e) Insert the screwdriver between the panel and the trim and remove the clips.
(f) Pull the trim upwards to remove it.
(g) Disconnect the connectors.





(h) Remove four screws and the side ventilator duct.
(i) Remove ten screws and the door pocket.
(j) Remove three screws and the speaker grill.
(k) Remove three screws and the armrest base panel.
(l) Remove courtesy light.





3. REMOVE SPEAKER
(a) Remove three screws and the speaker.
(b) Disconnect the connector.





4. REMOVE DOOR BELT MOULDING
(a) Remove the screw from the front edge of the moulding.
(b) Pry loose the clips from the edge of the panel and remove the moulding.





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

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





6. REMOVE OUTSIDE REAR VIEW MIRROR
(a) Remove the upper bracket garnish.
(b) Remove the screw and the speaker.
(c) Remove two screws and the mirror.
(d) Disconnect the connector.





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

8. REMOVE WINDOW OPENING PLATE

9. REMOVE SERVICE HOLE COVER
Remove the cover by pulling at the edge by hand.

HINT: Do not tear the cover.





10. DISCONNECT OPENING CONTROL LINK AND INSIDE LOCKING LINK
(a) Using a clip remover, remove the clip.
(b) Disconnect the opening control link and the inside locking link.





11. REMOVE DOOR GLASS STOPPERS
Remove two nuts and two stoppers.

12. REMOVE DOOR GLASS





(a) Remove three bolts.





(b) Pull the door glass out of the panel carefully.





13. REMOVE DOOR INSIDE PANEL PLATE
Remove the bolt and the plate.





14. REMOVE WINDOW REGULATOR
(a) Remove eight nuts and the regulator.
(b) Disconnect the connector.





15. REMOVE DOOR LOCK
(a) Disconnect the two links from the outside handle and key cylinder.
(b) Disconnect the connector.
(c) Remove three screws and the door lock.





16. REMOVE OUTSIDE HANDLE AND KEY CYLINDER
(a) Remove two bolts and the handle
(b) Remove the bolt and the key cylinder from the handle.

17. REMOVE SIDE PROTECTION MOULDING





18. REMOVE FRONT DOOR MIRROR BRACKET
Remove two bolts, the nut and the bracket.





19. REMOVE DOOR INSIDE PANEL FRAME
Remove three screws and the frame





DOOR GLASS REPLACEMENT

1. REMOVE FOLLOWING PARTS:
(a) Nut
(b) Stabilizers

2. REPLACE DOOR GLASS

3. INSTALL DOOR GLASS PARTS
Install the parts by following removal sequence in reverse.

FRONT DOOR ASSEMBLY





1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE
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.





2. INSTALL DOOR INSIDE PANEL FRAME
Install the frame with three screws.





3. INSTALL FRONT DOOR MIRROR BRACKET
Install the bracket with two bolts and the nut.

4. INSTALL SIDE PROTECTION MOULDING





5. INSTALL OUTSIDE HANDLE AND KEY CYLINDER
(a) Install the key cylinder to the outside handle with the bolt.
(b) Install the handle with two bolts.





6. INSTALL DOOR LOCK
(a) Apply adhesive to three screws.

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

(b) Install the door lock with three screws.
(c) Install the two links to the outside handle and key cylinder.
(d) Connect the connector.

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





7. INSTALL WINDOW REGULATOR
(a) Install the regulator with eight nuts.

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

(b) Connect the connector.





8. INSTALL DOOR INSIDE PANEL PLATE
Install the plate with the bolt.

9. INSTALL DOOR GLASS





(a) Insert the glass inside the door panel.

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





(b) Temporarily tighten three bolts.





10. INSTALL DOOR GLASS STOPPERS
Install two stoppers with two bolts.





11. CONNECT OPENING CONTROL LINK AND INSIDE LOCKING LINK.
(a) Connect the opening control link and the inside locking link with the door lock.
(b) Install the clip.

12. ADJUST DOOR GLASS





(a) Adjust lateral position of upper part of door glass. Loosen the two nuts, then adjust the stud bolts using a hexagon wrench.





(b) Adjust the front/rear position and the horizontal inclination of the door glass. Loosen the three nuts, then adjust the door glass.





(c) After adjustment is performed, check the following items:
- When the door is closed with the door glass then fully closed or else the door glass is fully closed with the door then closed, check that cross-section A- A and B-B are as specified in the illustration.
- When the door glass is fully closed and the door then closed, check that the weatherstrip is not pinched and that the door glass is not in contact with the roof drip moulding.
- When the door glass is fully closed, check that the outside edge of the door glass is in contact with the weatherstrip at the front pillar and roof side and that the edge of the glass cannot be seen.
- Check that the door glass is not loose when it is half open.
- When the door glass is rising up, check that the door glass and roof side weatherstrip are parallel and that the door glass contacts the two upper plates.
- Check that the door glass moves up and down smoothly over all areas.





13. ADJUST FRONT DOOR MIRROR BRACKET
(a) Remove the bolt.
(b) Rotate the nut and adjust the lateral position of the mirror bracket.
(c) Check that the bracket is aligned with the angle of the door glass.





14. INSTALL SERVICE HOLE COVER
Seal the service hole cover with adhesive.

HINT: Bring out the links through the service hole cover.





15. INSTALL DOOR INSIDE HANDLE
(a) Install the handle with three screws.
(b) Connect two links.





16. INSTALL DOOR BELT MOULDING
(a) Install the claw of the clips into the upper panel slit and push the moulding onto the panel.
(b) Install the screw to the moulding.





17. INSTALL DOOR WEATHERSTRIP
Push down on the eighteen clips and install the weatherstrip.





18. INSTALL OUTSIDE REAR VIEW MIRROR
(a) Connect the connector.
(b) Install the mirror with two screws.
(c) Install the speaker with the screw.
(d) Install the upper bracket garnish.





19. INSTALL SPEAKER
(a) Connect the connector.
(b) Install the speaker with three screws.

20. INSTALL DOOR TRIM
(a) Install courtesy light.





(b) Install the armrest base panel with three screws.
(c) Install the speaker grill with three screws.
(d) Install the door pocket with ten screws.
(e) Install the side ventilator duct with four screws.





(f) Insert the upper edge of the trim from above, tap the trim by hand fix it in place with the clips. then connect the connectors.
(g) Install two clips.
(h) Install two screws and the cap.
(i) Install the armrest cover.





21. INSTALL DOOR INSIDE HANDLE BEZEL
Install the door inside handle bezel.