Front Door: Service and Repair
Front Door:
OVERHAUL
HINT:
- Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the negative (-) terminal cable from the battery. After adjustment, inspect the SRS warning lamp, the side airbag system and the curtain shield airbag system for normal operation.
- 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 LH side and RH side.
- The procedures listed below are for the RH side.
- A bolt without a torque specification is shown in the standard bolt chart.
1. w/ Side airbag system and curtain shield airbag system:
DISCONNECT BATTERY NEGATIVE TERMINAL
a. Turn the ignition switch OFF.
b. Disconnect the negative (-) terminal cable from the battery.
CAUTION: Work must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source. If work is started within 90 seconds of disconnecting the negative (-) terminal battery and turning the ignition switch OFF, the SRS may deploy.)
2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Using a screwdriver, disengage the clip and claw, and remove the garnish.
HINT: Tape the screwdriver tip before use.
3. REMOVE ASSIST GRIP COVER LH
a. Using a screwdriver, disengage the 11 claws and remove the grip cover.
HINT: Tape the screwdriver tip before use.
4. REMOVE FRONT ARMREST BASE PANEL UPPER LH
a. Driver's side:
1. Using a screwdriver, disengage the clip and 4 claws, and remove the armrest base panel together with the window regulator master switch.
HINT: Tape the screwdriver tip before use.
2. Disconnect the switch connector.
3. Remove the 3 screws and window regulator master switch from the armrest base panel upper.
NOTE: Be careful when removing the screw as the master switch may fall and become damaged.
b. Passenger's side:
1. Using a screwdriver, disengage the clip and 5 claws, and remove the armrest base panel together with the switch.
HINT: Tape the screwdriver tip before use.
2. Disconnect the switch connector.
3. Using a screwdriver, disengage the 2 claws and remove the power window regulator switch.
HINT: Tape the screwdriver tip before use.
NOTE: Be careful when disengaging the claws as the switch may fall and become damaged.
5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Cover the areas indicated by the arrows in the illustration with protective tape to prevent damage to the door panel.
b. Remove the 2 screws.
c. Using a screwdriver, disengage the 9.
HINT: Tape the screwdriver tip before use.
d. Hold the door trim with your hands in the areas indicated by the arrows in the illustration.
e. Horizontally pull out the door trim to disengage the 4 clips.
NOTE: In order to prevent damage to the 2 pins, be sure to keep the door trim horizontal while removing it.
6. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
7. REMOVE FRONT DOOR BELT MOULDING LH
8. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY LH
a. Using a drill of less than Dia 4 mm (0.16 in.), drill out the 3 rivet heads and remove the speaker.
NOTE:
- Be sure to gently place the drill perpendicular to the rivet, otherwise the rivet hole and the drill itself will be damaged.
- Be careful as the cut rivet will be 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 rivet and dust from the inside of the door.
9. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH
a. Remove the weatherstrip inner.
10. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH
a. Using a screwdriver, disengage claw A.
HINT: Tape the screwdriver tip before use.
b. Move the inside handle in the direction indicated by the arrow mark in the illustration. This will release the claw and allow removal of the inside handle.
c. Disconnect the 2 cables from the inside handle.
11. REMOVE FRONT DOOR SERVICE HOLE COVER LH
a. w/ No. 2 speaker:
Remove the screw and No. 2 speaker.
b. Remove the service hole cover.
NOTE: Remove the remaining tape on the door side.
12. w/ Side airbag system and curtain shield airbag system:
REMOVE SIDE AIRBAG SENSOR ASSEMBLY LH
a. Remove the 2 nuts and sensor.
HINT: Remove the sensor through the service hole.
13. REMOVE FRONT DOOR STIFFENER CUSHION NO.2
a. Remove the 2 bolts and cushion.
HINT: Remove the cushion through the service hole.
14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH
HINT: Insert a cushion inside the door panel to prevent the glass from being scratched.
a. Driver's side:
Temporarily install the window regulator master switch.
b. Passenger's side:
Temporarily install the power window regulator switch.
c. Move the door glass until the 2 bolts appear in the service holes.
d. Remove the 2 bolts.
NOTE: Be careful when removing the bolts as the glass may fall and become damaged.
e. Remove the door glass in the direction indicated by the arrow marks in the illustration.
NOTE: Be careful not to damage the glass.
f. Driver's side:
Remove the window regulator master switch.
g. Passenger's side: Remove the power window regulator switch.
15. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the connector.
b. Loosen bolt A.
c. Remove the 5 bolts and 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.
d. Remove bolt A.
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 bolt and frame.
HINT: Remove the frame through the service hole.
NOTE: Be careful when removing the bolt as the frame may fall and become damaged.
18. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH
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.
19. REMOVE FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Using a torx socket wrench (T30), remove the 3 screws and door lock.
HINT: Remove the door lock through the service hole.
NOTE: Be careful when removing the screws as the door lock may fall and become damaged.
20. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.
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.
21. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
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.
c. Using pliers, remove the clips and frame, as shown in the illustration.
HINT: Remove the frame through the service hole.
NOTE: Be sure to remove the outside handle frame together with the clips, as the clips will be damaged if they remain attached to the door panel.
d. Remove the lock control rod.
22. REMOVE FRONT DOOR OUTSIDE HANDLE PAD FRONT
a. Disengage the 2 claws and remove the pad.
23. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR
a. Disengage the 2 claws and remove the pad.
24. REMOVE FRONT DOOR CHECK ASSEMBLY LH
a. Remove the bolt, 2 nuts and the door check.
HINT: Remove the check through the service hole.
25. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, remove the 2 clips indicated by the 2 arrow marks in the illustration.
b. Using a clip remover, disengage the 17 clips and remove the weatherstrip.
HINT: If clips are damaged during removal, replace them.
26. 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: 5.5 N.m (56 kgf.cm, 49 in.lbf)
c. Apply adhesive to a bolt.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install the door check to the body panel with the bolt.
Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
HINT: Install the door check so that the rivet head is facing up.
27. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Install the front door lock open rod.
b. Apply MP grease to the sliding areas of the frame.
c. Using a torx socket wrench (T30), install the frame with the screw.
Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)
28. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Install the outside handle pad front and rear.
b. Pull and hold the bellcrank lever of the frame as shown in the illustration.
c. Install the handle by pushing it in the direction of in 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.
29. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the door lock.
b. Install a new door lock wire harness packing.
NOTE:
- When reinstalling the door lock, always use new packing.
- Do not allow grease or dirt to contaminate the gap between the door panel and packing.
- Old packing or damaged packing cannot effectively protect against water, which can damage the door lock.
c. Insert the control rod into the door lock, and then set it to the door panel.
NOTE: Make sure that the rod is securely engaged with the lock.
d. Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
e. Using a torx socket wrench (T30), install the door lock with the 3 screws.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
f. Connect the door lock connector.
30. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), install the cover (with the door lock key cylinder installed) with the screw.
Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)
b. Install the hole plug.
31. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Install the frame with the bolt.
Torque: 8.5 N.m (87 kgf.cm, 75 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: 5.4 N.m (55 kgf.cm, 48 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. Loosely screw bolt A onto the window regulator.
c. Insert the window regulator into the door panel. Use bolt A to hang the window regulator on the door panel.
d. Install the window regulator with the 5 bolts and tighten bolt A.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
NOTE: Be careful not to drop the window regulator as it may become damaged.
34. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
a. Install the glass run.
NOTE: Be careful not to damage the glass.
b. Insert the door glass into the door panel along the glass run as indicated by the arrow marks in the illustration.
c. Install the door glass to the window regulator with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
35. w/ Side airbag system and curtain shield airbag system:
INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH
a. Turn the ignition switch OFF.
b. Disconnect the battery negative (-) terminal.
CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation.
c. Install the sensor with the 2 nuts.
Torque: 9.0 N.m (92 kgf�cm, 80 in.lbf)
NOTE:
- If the side airbag sensor assembly LH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
- When installing the side airbag sensor assembly LH, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts.
d. Connect the connector to the sensor.
e. Check that there is no looseness in the installation parts of the sensor.
f. Connect the negative (-) terminal cable to the battery.
g. Inspect the SRS warning lamp.
h. Perform the initialization.
36. INSTALL FRONT NO.1 SPEAKER ASSEMBLY
a. Install the front speaker to the door.
b. Using an air riveter or hand riveter, install the front speaker.
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 speaker as this will cause the rivet to be loose.
- Do not have any space between the rivet head and the speaker. The rivet head must be completely flat against the speaker.
- Do not have any space between the speaker and door. Firmly hold together the 2 items while installing the rivet.
37. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. 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.
b. Connect the 2 connectors.
38. w/ Side airbag system and curtain shield airbag system:
CONNECT BATTERY NEGATIVE TERMINAL
a. Connect the negative (-) terminal cable to the battery.
b. Inspect the SRS warning lamp.
c. Initialize both systems.
HINT: When disconnecting the battery terminal, initialize the following system after the terminal is reconnected.
- Power window control system
- Sliding roof system
39. RESET POWER WINDOW REGULATOR MOTOR