Front Door: Service and Repair

DISASSEMBLY




1. w/o Power Window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator handle and plate.




2. REMOVE DOOR INSIDE HANDLE
(a) Remove the screw and slide the handle forward.
(b) Disconnect the handle from the 2 control links and remove the handle.




3. REMOVE DOOR TRIM
(a) Remove the armrest.
(b) Remove the 2 screws.
(c) Inset a screwdriver between the door and the door trim to pry out.

NOTICE: Be careful not to damage the door and door trim.

HINT: Tape the screwdriver tip before use.
(d) Pull the trim upwards to remove it.




4. REMOVE REAR VIEW MIRROR
(a) w/ Manual Remote Control Mirror:
With the front side window fully open, remove the knob cover with a screwdriver as shown in the illustration.
(b) w/ Manual Remote Control Mirror:
Remove the screw and knob.
(c) Using a screwdriver, pry off the Inner cover.
HINT: Tape the screwdriver tip before use.
(d) Remove the 3 nuts and mirror.




5. REMOVE DOOR BELT MOULDING
Pry out the clips from the edge of the mounding and remove the moulding.

6. REMOVE SPEAKER




7. REMOVE SERVICE HOLE COVER
HINT: At the time of reassembly, please refer to the following item.
Bring out the link through the service hole cover.

8. REMOVE THESE PARTS:
(a) Door glass run
(b) Door glass
(c) Rear lower frame




9. REMOVE WINDOW REGULATOR
(a) Using a hammer, tap out the mandrels from the inside to the outside of the vehicle.




(b) Using a drill of less than 6.8mm (0.268 in.), drill out the rivet heads and remove the window regulator
HINT: Do not drill the door inner hole.
(c) Remove the regulator through the service hole.
(d) Using a vaccum cleaner, remove the drilled rivets and their dust from the inside of the door.




HINT: At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding surface and gears of the window regulator.




HINT: At the time of reassembly, please refer to the following item.
Using an air riveter, strike rivets into the door frame to install the window regulator to the door frame.




CAUTION: At the time of reassembly, please refer to the following item.
To avoid personal injury and short of the wiring when installing 6.4mm (0.252 in.) rivets, keep your hands and wire harness out of the 20mm (0.79 in.) radius that the caulked 6.4mm (0.252 in.) river will cover.




NOTICE: At the time of reassembly, please refer to the following item.
If the rivet is not positioned perpendicularly, it will bend the mandrel.
If the trigger is pulled then, it may damage SST.




10. REMOVE DOOR LOCK
(a) Remove the door lock control knob from the link.
(b) Disconnect the 2 links from the outside handle and door lock cylinder.
(c) Remove the 3 screws.
Torque: 5.4 Nm (55 kgf cm, 48 in. lbf)
HINT: At the time of reassembly, please refer to the following item.
Apply adhesive to the 3 screws.
Part No. 08833-00070, THREE BOND 1342 or equivalent.




HINT: At the time of reassembly, please refer to the following item.
Apply MP Grease to the sliding and rotating parts of the door lock.

11. REMOVE THESE PARTS:
(a) Outside handle
(b) Door lock cylinder

REASSEMBLY

Reassembly is in the reverse order of disassembly.