Front Door: Service and Repair
Front Door:
OVERHAUL
HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.
- A bolt without a torque specification is shown in the standard bolt chart.
1. REMOVE DOOR INSIDE HANDLE BEZEL NO.2 LH
a. Using a screwdriver, disengage the 3 claws and remove the bezel.
HINT: Tape the screwdriver tip before use.
2. Driver's side:
REMOVE FRONT DOOR ARMREST BASE PANEL UPPER
a. Using a screwdriver, pry the armrest panel assembly.
HINT: Tape the screwdriver tip before use.
b. Remove the 3 screws and power window regulator master switch.
c. Remove the 2 screws and armrest base panel lower from the armrest base panel upper.
3. Passenger's side:
REMOVE FRONT DOOR ARMREST BASE PANEL UPPER
a. Using a screwdriver, pry the armrest panel assembly.
HINT: Tape the screwdriver tip before use.
b. Using a screwdriver, disengage the 2 claws and remove the lock control switch from the armrest panel assembly.
HINT: Tape the screwdriver tip before use.
c. Using a screwdriver, disengage the 2 claws and remove the power window switch from the armrest assembly.
HINT: Tape the screwdriver tip before use.
d. Remove the 2 screws and armrest base panel lower from the armrest base panel upper.
4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the 7 screws as shown in the illustration.
b. Using a screwdriver, disengage the 4 clips.
HINT: Tape the screwdriver tip before use.
c. Remove the trim board upward.
HINT: In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration.
d. Disconnect the 2 cables from the inside handle.
e. Remove the screw.
f. Using a screwdriver, disengage the 2 claws.
HINT: Tape the screwdriver tip before use.
g. Remove the inside handle.
h. Using a screwdriver, disengage the 2 clips and remove the courtesy lamp.
i. Remove the 2 screws and seat memory switch.
j. Remove the 3 screws and vent seal.
k. Remove the 2 screws and door pocket.
5. REMOVE DOOR FRAME GARNISH LH
a. Using a clip remover, disengage the 2 clips and remove the garnish.
6. REMOVE FRONT DOOR SERVICE HOLE COVER LH
a. Remove the 2 screws and door electrical key oscillator.
b. Remove the service hole cover.
NOTE: Remove the remaining tape on the door side.
7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Disconnect the connector.
b. Remove the 3 bolts and mirror.
NOTE: Be careful when removing the bolts as the mirror may fall and become damaged.
8. REMOVE FRONT DOOR ECU
a. Disconnect the connector.
b. Remove the 2 screws and ECU.
9. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
10. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH
11. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH
12. REMOVE FRONT DOOR WINDOW FRAME MOULDING FRONT LH
13. REMOVE FRONT DOOR GLASS RUN LH
a. Using a drill of less than dia 4 mm (0.16 in.), drill out the heads of the 5 rivets and remove the glass run.
NOTE:
- Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
- Be careful as the cut rivet will become very hot.
b. Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
c. Using a vacuum cleaner, remove the drilled rivets and dust from the inside of the door.
14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH
HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched.
a. Move the door glass until the bolts appear in the service holes.
b. Remove the 2 bolts holding the door glass to the window regulator.
NOTE: Be careful when removing the bolts as the glass may fall and become damaged.
c. Move the glass as shown in the illustration to remove it.
NOTE: Be careful not to damage the glass.
15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Remove the 6 bolts and window regulator.
HINT: Remove the window regulator through the service hole.
NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.
16. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT
a. Place matchmarks on the window regulator motor bracket and regulator gear.
b. Using a torx driver (T25), remove the 3 screws and motor.
17. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Remove the 2 bolts and frame.
HINT: Remove the frame through the service hole.
NOTE: Be careful when removing the bolts as the frame may fall and become damaged.
18. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH
a. Remove the 2 bolts and frame.
HINT: Remove the frame through the service hole.
NOTE: Be careful when removing the bolts as the frame may fall and become damaged.
19. REMOVE DOOR OUTSIDE HANDLE COVER ASSEMBLY
a. Remove the hole plug.
b. Using a torx socket wrench (T30), loosen the screw and remove the cover with the door lock key cylinder installed.
20. REMOVE FRONT DOOR LOCK ASSEMBLY LH
a. Disconnect the door lock connector.
b. w/o Door closer:
Using a torx socket wrench (T30), remove the 3 screws and door lock.
c. w/ Door closer:
Using a torx socket wrench (T30), remove the 5 screws and door lock.
HINT: Remove the door lock through the service hole.
NOTE: Be careful when removing the bolts as the door lock may fall and become damaged.
d. Remove the door remote control cable and door inside locking cable.
21. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Disconnect the connector.
b. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
c. Remove the outside handle pad front and rear.
NOTE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.
22. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Remove the nut.
b. Slide the outside handle frame to remove it.
HINT: Remove the outside handle frame through the service hole.
c. Remove the lock open rod from the outside handle frame.
23. REMOVE FRONT DOOR CHECK ASSEMBLY LH
a. Remove the cover.
b. Remove the bolt, 2 nuts and door check.
HINT: Remove the door check through the service hole.
NOTE: Be careful when removing the bolts as the door check may fall and become damaged.
24. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clips and remove the weatherstrip.
HINT: If clips are damaged during removal, replace them.
25. INSTALL FRONT DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding areas of the door check.
b. Install the door check to the door panel with the 2 nuts.
Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)
c. Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install the door check to the body panel with the bolt.
Torque: 27 Nm (275 kgf.cm, 20 ft.lbf)
e. Install the cover.
26. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Install the lock open rod to the outside handle frame.
b. Install the frame with the nut.
Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)
NOTE: A cover should be inserted between the nut and the door panel.
27. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Install the outside handle pad front and rear.
b. Pull and hold the release plate of the frame as shown in the illustration.
c. Install the handle by pushing it in the direction indicated by the arrow marks in the illustration.
NOTE: If the release plate is not pulled and held when installing the handle, the release plate will interfere with the handle and become damaged.
28. INSTALL FRONT DOOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the door lock.
b. Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
c. Using a torx socket wrench (T30), install the door lock with the 3 screws.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)
d. w/ Door closer:
Using a torx socket wrench (T30), install the 2 screws.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)
e. Connect the door lock connector.
29. INSTALL DOOR OUTSIDE HANDLE COVER ASSEMBLY
a. Using a torx socket wrench (T30), install the outside handle cover with the screw.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)
b. Install the hole plug.
30. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH
a. Install the frame with the 2 bolts.
Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)
31. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Install the frame with the 2 bolts.
Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)
32. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT
a. Align the matchmarks. Keep them aligned until the window glass installation is complete.
b. Using a torx driver (T25), install the motor with the 3 screws.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)
33. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the window regulator.
NOTE: Do not apply grease to the spring of the window regulator.
b. Install the window regulator with the 6 bolts.
Torque: 11 Nm (115 kgf.cm, 8 ft.lbf)
34. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Insert the door glass into the door panel along the glass run in the direction indicated by the arrow mark in the illustration.
b. Install the door glass to the window regulator with the 2 bolts.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)
35. INSTALL FRONT DOOR GLASS RUN LH
a. Using a hand riveter or an air riveter, install the glass run to the door with the 5 rivets.
NOTE:
- Do not prize the riveter. The riveter will be damaged and the mandrel will bend.
- Do not tilt the riveter when fastening the rivet to the glass run as this will cause the rivet to be loose.
- Do not have any space between the rivet head and the glass run. The rivet head must be completely flat against the glass run.
- Do not have any space between the glass runs. Firmly hold together the 2 items while installing the rivet.
b. Connect the speaker connector.
36. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Install the mirror with the 3 bolts.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)
b. Connect the mirror connector.
37. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door as shown in the illustration.
b. Install a new service hole cover.
HINT:
- When installing the service hole cover, pull out the links and connectors through the service hole cover.
- There should be no wrinkles or folds after attaching the service hole cover.
- After attaching the service hole cover, check the sealing quality.
c. Connect the 2 connectors and install the wire.
d. Install the door electrical key oscillator with the 2 screws.
38. INITIALIZE POWER WINDOW SYSTEM [1][2]Programming and Relearning