Front Door: Service and Repair

FRONT DOOR

Front Door:

DISASSEMBLY

HINT:
- Use the same procedures 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 ASSIST GRIP COVER LH

a. Using a screwdriver, detach 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, detach the clip and 5 claws, and remove the armrest base panel upper LH 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 LH.

NOTICE: Be careful when removing the screws as the master switch may fall and become damaged

b. Passenger's side:
1 Using a screwdriver, detach the clip and 5 claws, and remove the armrest base panel upper RH together with the window regulator switch.

HINT: Tape the screwdriver tip before use.

2 Disconnect the switch connector.
3 Using a screwdriver, detach the 2 claws and remove the power window regulator switch from the armrest base panel upper RH.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful when detaching the claws as the switch may fall and become damaged.

5. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG

a. Using a screwdriver, detach the claw, and remove the front door inside handle bezel plug.

6. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

a. Prevent damage to the door panel by applying protective tape to the areas indicated by the arrows in the illustration.
b. Remove the 3 screws.
c. Using a screwdriver, detach the 9 clips.

HINT: Tape the screwdriver tip before use.

d. Prepare to remove the door trim by holding the locations indicated by the arrows in the illustration.
e. Horizontally pull out the door trim to detach the 4 clips.

NOTICE: To prevent damage to the 2 pins, be sure to keep the door trim horizontal while removing it.

7. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
8. REMOVE FRONT DOOR BELT MOULDING LH
9. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
10. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (w/ Front No. 2 Speaker)
11. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH

a. Remove the weatherstrip inner.

12. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH

a. Using a screwdriver, detach the claw.

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.

13. REMOVE FRONT DOOR SERVICE HOLE COVER LH

a. Remove the service hole cover.

NOTICE: Remove the remaining tape on the door side.

14. REMOVE SIDE AIRBAG SENSOR ASSEMBLY LH (w/ Side Airbag System and Curtain Shield Airbag System)

15. REMOVE FRONT DOOR NO. 1 STIFFENER CUSHION

a. Remove the 2 bolts and cushion.

HINT: Remove the sensor through the service hole.

16. 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.

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's side:
Remove the window regulator master switch.
g. Passenger's side:
Remove the power window regulator switch.

17. 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.

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

d. Remove bolt A.

18. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT

a. Place matchmarks on the window regulator motor bracket and regulator gear.

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

19. 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 bolts as the frame may fall and become damaged.

20. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH

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

21. REMOVE FRONT DOOR LOCK ASSEMBLY LH

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

HINT: Remove the door lock through the service hole.

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

22. 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.

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

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

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

b. Using pliers, squeeze the clip and remove the frame.

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 control rod.

24. REMOVE FRONT DOOR OUTSIDE HANDLE PAD FRONT

a. Detach the 2 claws and remove the pad.

25. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR

a. Detach the 2 claws and remove the pad.

26. REMOVE FRONT DOOR CHECK ASSEMBLY LH

a. Remove the bolt, 2 nuts and the door check.

HINT: Remove the check through the service hole.

27. 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, detach the 17 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 17 clips.
b. Attach the 2 clips indicated by the 2 arrow marks in the illustration.

2. 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, 46 in.lbf) for bolt A

c. Apply adhesive to 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: 30 N.m (306 kgf.cm, 22 ft.lbf)

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

3. INSTALL FRONT DOOR OUTSIDE HANDLE PAD REAR

a. Attach the 2 claws to install the pad.

4. INSTALL FRONT DOOR OUTSIDE HANDLE PAD FRONT

a. Attach the 2 claws to install the pad.

5. 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 T30 "torx" socket, install the frame with the screw.

Torque: 4.0 N.m (41 kgf.cm, 35 in.lbf)

6. INSTALL FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH

a. Pull and hold the bellcrank lever of the frame as shown in the illustration.

b. Install the handle by pushing it in the direction of the arrow marks in the illustration.

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

7. INSTALL FRONT DOOR 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.

CAUTION
- 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 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.

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, 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.

8. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH

a. Using a T30 "torx" socket, install the cover (with the door key cylinder installed) with the screw.

Torque: 4.0 N.m (41 kgf.cm, 35 ft.lbf)

b. Install the hole plug.

9. 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)

10. 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 T25 "torx" driver, install the motor with the 3 screws.

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

11. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY 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 N.m (82 kgf.cm, 71 in.lbf)

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

12. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH

a. Install the glass run.

CAUTION: Be careful not to damage the glass.

b. Insert the door glass into the door panel along the glass run as indicated by the arrows in the illustration.

c. Install the glass to the window regulator with the 2 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

13. INSTALL FRONT DOOR NO. 1 STIFFENER CUSHION

a. Install the stiffener cushion to the front door with the 2 bolts.

14. INSTALL SIDE AIRBAG SENSOR ASSEMBLY LH (w/ Side Airbag System and Curtain Shield Airbag System)
15. 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 that it is installed properly.

b. Connect each connector.

16. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY 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.

17. INSTALL FRONT DOOR GLASS WEATHERSTRIP INNER LH
18. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (w/ Front No. 2 Speaker)
19. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY
20. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
21. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH

a. Attach the 4 clips and install the trim board.

b. Attach the 9 clips and install the 2 screws.

22. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

a. Attach the claw and install the front door inside handle bezel plug.

23. INSTALL FRONT ARMREST BASE PANEL UPPER LH

a. Driver's side:
1 Install the window regulator master switch to the armrest base panel upper LH with the 3 screws.
2 Connect the switch connector.

3 Attach the clip and 5 claws to install the armrest base panel upper LH together with the window regulator master switch.

b. Passenger's side:
1 Install the power window regulator switch to the armrest base panel upper RH with the 2 screws.
2 Connect the connector.
3 Attach the clip and 5 claws to install the armrest base panel upper RH together with the power window regulator switch.

24. INSTALL ASSIST GRIP COVER LH

a. Install the grip cover and attach the 11 claws.

25. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH LH

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

26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
27. INSPECT SRS WARNING LIGHT
a. Check the SRS warning light.

28. PERFORM INITIALIZATION
a. Perform initialization.

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