Disassembly and Reassembly

FRONT DOOR DISASSEMBLY





1. REMOVE DOOR INSIDE HANDLE BEZEL
(a) Using a screwdriver, pry out the bezel.
(b) Pull the bezel backward and remove it.

HINT: Tape the screwdriver, tip before use.





2. REMOVE DOOR TRIM
(a) Remove the cap and screw.
(b) Remove the 2 cap and clips.
(c) Remove the cap and screw.
(d) Insert a screwdriver between the panel and door trim and remove the 4 clips.
(e) Pull the trim upwards to remove it.

HINT: Tape the screwdriver tip before use.





3. REMOVE THESE PARTS:
(a) Speaker
(b) Door belt moulding
(c) Weatherstrip
(d) Outside rear view mirror

4. REMOVE DOOR INSIDE HANDLE
(a) Remove the 3 screws.
(b) Disconnect the 2 links from the handle.





5. REMOVE SERVICE HOLE COVER

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





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

7. REMOVE DOOR GLASS STOPPERS





8. REMOVE DOOR GLASS
(a) Remove the 3 bolts.
(b) Pull the door glass out off the panel carefully.

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





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

ASSEMBLY HINT: Tighten the bolt after door glass adjustment.





10. REMOVE WINDOW REGULATOR
(a) Remove the 8 nuts and regulator.

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

(b) Disconnect the connector.





ASSEMBLY HINT: Apply MP grease to the sliding surface and gears of the window regulator.

ASSEMBLY NOTICE: Do not apply MP grease to the spring of the window regulator.





11. REMOVE DOOR LOCK
(a) Disconnect the 2 links from the outside handle and key cylinder.
(b) Disconnect the connector.
(c) Remove the 3 screws.

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





ASSEMBLY HINT: Apply adhesive to the 3 screws. Part No.08833-00070, THREE BOND 1324 or equivalent.

12. REMOVE THESE PARTS:
(a) Outside handle and key cylinder
(b) Side protection moulding
(c) Front door mirror bracket
(d) Door inside panel frame





DOOR GLASS REPLACEMENT
1. REMOVE THESE PARTS:
(a) Nut
(b) Stabilizers

2. REPLACE DOOR GLASS

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

DOOR GLASS ADJUSTMENT

1. ADJUST DOOR GLASS





(a) Adjust lateral position of upper part of the door glass. Loosen the 2 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 3 nuts. then adjust the door glass.





(c) After adjustment is done. check the following items:
- When the door is clo8ed with the door glass then fully closed or el8e 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.
- With the door glass fully closed and the door is 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 2 upper plates.
- Check that the door glass moves up and down smoothly over all areas.





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

WINDOW REGULATOR REPLACEMENT

1. REMOVE COVER PLATE





(a) Screw Type:
Remove the 2 screws and remove the cover plate.

HINT: The screws and cover plate can be used again.





Crimped Type:

HINT: Tape a screwdriver tip before use.
Using the screwdriver, pry up the cover plate tab and remove the cover plate.

NOTICE: Do not damage the motor housing.

HINT: The cover plate is not usable.





(b) Remove the drum and wire guide from motor.

NOTICE: Do not use a screwdriver etc. to help remove them.





2. INSTALL WINDOW REGULATOR

NOTICE:
- To prevent the drum and cable from coming off, do not tilt the drum, subject it to shocks or use force on it.
- If the cable comes off the drum, do not remind the cable and do not reuse it.
- After installing the window regulator, do not operate it by itself as some types of regulator do not have a stopper.

(a) Insert the window regulator drum into the motor housing.





Using Holding Tool A:
- Apply MP grease inside the motor housing.





- With the holding tool installed, motor the holding tool with the motor housing.
- Push down on the wire guide and drum, and insert the drum into the motor housing.

NOTICE: If you can not insert the drum into the motor, slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.

- Apply MP grease to the side of the drum.





Using Holding Tool B:
- Apply MP grease inside the motor housing.





- With the holding tool installed, partially insert the drum into the motor housing.
- Remove the holding tool, and insert the drum into the motor housing.

NOTICE: If you can not insert the drum into the motor. slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.

- Apply MP grease to the side of the drum.





(b) Install the cover plate.

Screw Type:
Install the cover plate using the 2 screws.





Crimped Type:
Use motor pump pliers to crimp the tab of the cover plate.

NOTICE:
- Use a new cover plate. (Non-reusable part)
- Do not hit the cover plate with a hammer, etc.
- Do not damage the motor housing.

FRONT DOOR ASSEMBLY
Assembly is in the reverse order of disassembly.