Front Door: Service and Repair

FRONT DOOR

COMPONENTS

Front Door:

DISASSEMBLY

HINT:
- Use the same procedure for the RH side and LH side.
- The procedures listed below are for the LH side.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH

(a) Using a screwdriver, detach the clip and claw, and remove the garnish.

HINT: Tape the screwdriver tip before use.

3. REMOVE FRONT ARMREST BASE PANEL UPPER LH

(a) Remove the screw.
(b) Using a screwdriver, detach the 12 claws and 2 clips, and remove the armrest base panel together with the switch.

HINT: Tape the screwdriver tip before use.

(c) Disconnect the switch connector.

(d) Driver side: Remove the 3 screws and switch from the armrest base panel upper.

NOTICE: Be careful when removing the screw as the master switch may fall and became damaged.

(e) Passenger side:
(1) Detach the 2 claws and power window switch from the armrest base panel upper.
(2) Detach the 2 claws and door lock switch from the armrest base panel upper.

4. REMOVE FRONT DOOR TRIM BOARD SUBASSEMBLY LH

(a) Remove the screw and clip A as shown in the illustration.
(b) Using a clip remover, detach the 7 clips.
(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) Using a screwdriver, detach the claws and remove the weatherstrip inner.

HINT: Tape the screwdriver tip before use.

5. REMOVE FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH

(a) Using a screwdriver, detach 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 2 claws and allow removal of the inside handle.
(c) Disconnect the 2 cables from the inside handle.

6. REMOVE FRONT DOOR SERVICE HOLE COVER LH

(a) Remove the 2 bolts and trim bracket.

(b) Disconnect the 2 connectors.
(c) Using a screwdriver, remove the clip indicated by the arrow mark and remove the wire.

HINT: Tape the screwdriver tip before use.

(d) Remove the service hole cover.

7. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY
8. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
9. REMOVE FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH
10. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
11 REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH
(a) Driver side: Temporarily install the window regulator master switch.
(b) Passenger side: Temporarily install the power window regulator switch.
(c) Move the door glass until the bolts appear in the service holes.

(d) Remove the 2 bolts.

NOTICE: 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.

NOTICE: Be careful not to damage the glass.

(f) Driver side: Remove the window regulator master switch.
(g) Passenger side: Remove the power window regulator switch.

(h) Using a clip remover, remove the clip as shown in the illustration.
(i) Remove the glass run.

12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
(a) Disconnect the window regulator connector.
(b) Loosen bolt A shown in the illustration.

(c) Remove the 5 bolts and window regulator.

HINT: Remove the window regulator through the service hole.

NOTICE: Be careful when removing the bolts as the window regulator may fall and become damaged.

(d) Remove bolt A from the window regulator.

13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT

(a) Using a T25 "torx" driver, remove the 3 screws and motor.

14. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH

(a) Remove the bolt and frame.

HINT: Remove the frame through the service hole.

NOTICE: Be careful when removing the bolt as the frame may fall and become damaged.

15. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH

(a) Remove the bolt and frame.

HINT: Remove the frame through the service hole.

NOTICE: Be careful when removing the bolt as the frame may fall and become damaged.

16. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH

(a) Remove the hole plug.
(b) Using a T30 "torx" socket wrench, loosen the screw and remove the cover with the door lock key cylinder installed.

17. REMOVE FRONT DOOR WITH MOTOR LOCK ASSEMBLY LH

(a) Using a T30 "torx" socket wrench, remove the 3 screws and door lock.

HINT: Remove the door lock through the service hole.

NOTICE: Be careful when removing the bolts as door lock may fall and become damaged.

18. 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.
(b) Remove the outside handle pad front and rear.

NOTICE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.

19. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

(a) Using a T30 "torx" socket wrench, loosen the screw of the frame.

(b) Using pliers, pinch the clip and remove the handle frame, as shown in the illustration.

HINT: Remove the frame through the service hole.

NOTICE: 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.

(c) Remove the lock open rod.

20. REMOVE FRONT DOOR CHECK ASSEMBLY LH

(a) Remove the 3 bolts and door check.

HINT: Remove the check through the service hole.

21. REMOVE FRONT DOOR WEATHERSTRIP LH

(a) Using a clip remover, detach the clips and remove the weatherstrip.

HINT: If clips are damaged during removal, replace them.

REASSEMBLY

HINT:
- Use the same procedure 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. INSTALL FRONT DOOR WEATHERSTRIP LH
(a) Install the weatherstrip and attach the clips.

2. REMOVE FRONT DOOR CHECK ASSEMBLY LH

(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in.-lbf)

HINT: Install the door check so that the rivet head is facing upward.

(c) Apply adhesive to the threads of the bolt.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

(d) Install the check to the body panel with the bolt.
Torque: 30 Nm (306 kgf-cm, 22 in.-lbf)

3. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

(a) Install the lock open rod.
(b) Apply MP grease to the sliding areas of the frame.
(c) Using a T30 "torx" socket wrench, install the frame with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in.-lbf)

4. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH

NOTICE: If the release plate is not pulled and held when installing the handle, the release plate will interfere with the handle and become damaged.

(a) Install the outside handle pad front and rear.

(b) Install the handle by pushing it in the direction of the arrow mark in the illustration.

5. INSTALL FRONT DOOR WITH 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.

NOTICE:
- When reinstalling a 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. Water will damage the door lock.

(c) Install the control rod into the door lock, and then set it to the door panel.

NOTICE: 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 T30 "torx" socket wrench, install the door lock with the 3 screws.
Torque: 5.0 Nm (51 kgf-cm, 44 in.-lbf)
(f) Connect the door lock connector.

6. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH

(a) Using a T30 "torx" socket wrench, install the cover (with the door lock key cylinder installed) with the screw.
Torque: 4.0 Nm (41 kgf-cm, 37 in.-lbf)

(b) Install the hole plug.

7. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH

(a) Install the frame with the bolt.
Torque: 6.2 Nm (63 kgf-cm, 55 in.-lbf)

8. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH

(a) Install the frame with the bolt.
Torque: 6.2 Nm (63 kgf-cm, 55 in.-lbf)

9. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT

(a) Using a T25 "torx" driver, install the motor with the screws.
Torque: 5.4 Nm (55 kgf-cm, 48 in.-lbf)

10. INSTALL FRONT DOOR WINDOW REGULATOR SUBASSEMBLY LH

(a) Apply MP grease to the sliding and rotating areas of the window regulator.

NOTICE: 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 Nm (82 kgf-cm, 71 in.-lbf)

NOTICE: Be careful not to drop the window regulator as it may become damaged.

(e) Connect the window regulator connector.

11 INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

(a) Install the glass run.

NOTICE: Be careful not to damage the glass.

(b) Insert the door glass into the door panel along the glass run as indicated in the illustration.

(c) Install the door glass to the window regulator with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in.-lbf)

(d) Inspect operation of the power window.
(1) Connect the power window switch to the wire harness and turn the ignition switch ON.
(2) Use the UP and DOWN function several times.
12. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
13. INSTALL FRONT DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH
14. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
15. INSTALL NO. 2 FRONT SPEAKER ASSEMBLY
16. 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 trim bracket with the 2 bolts.
17. INSTALL FRONT DOOR INSIDE HANDLE SUBASSEMBLY LH

(a) Move the inside handle in the direction indicated by the arrow in the illustration to install the inside handle.
(b) Connect the 2 cables to the inside handle.

18. INSTALL FRONT DOOR TRIM BOARD SUBASSEMBLY LH

(a) Attach the claws to install the weatherstrip inner.
(b) Attach the 7 clips to install the trim board.
(c) Install the screw and clip A as shown in the illustration.

19. INSTALL FRONT ARMREST BASE PANEL UPPER LH

(a) Driver side:
(1) Install the window regulator master switch to the armrest base panel upper LH with the 3 screws.

(b) Passenger side:
(1) Attach the 2 claws to install the power window regulator switch.
(2) Attach the 2 claws to install the door lock switch.
(c) Connect the switch connector.

(d) Attach the 12 claws and 2 clips to install the armrest base panel together with the switch.
(e) Install the screw.

20. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

(a) Attach the clip and claw to install the garnish.

21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
22. PERFORM INITIALIZATION
(a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.