Front Door: Service and Repair
DISASSEMBLY1. REMOVE INSIDE HANDLE BEZEL
a. Using a screwdriver, remove the cover.
HINT: Tape the screwdriver tip before use.
b. Remove the screw.
c. Using a screwdriver, remove the inside handle bezel as shown in the illustration.
HINT: Tape the screwdriver tip before use.
2. REMOVE COURTESY LIGHT
3. REMOVE UPPER ARMREST BASE PANEL WITH POWER WINDOW SWITCH
a. Using a screwdriver, remove the upper armrest base panel with power window switch.
HINT: Tape the screwdriver tip before use.
b. Disconnect the connector.
c. Remove the 3 screws and power window switch from the upper armrest base panel.
4. REMOVE DOOR TRIM
a. Using a screwdriver, remove the 2 caps.
HINT: Tape the screwdriver tip before use.
b. Remove the 6 screws and clip.
c. Pull the trim upward to remove it.
d. Using a screwdriver, remove the front door inner weatherstrip from the front door trim.
e. Remove the 10 screws and front door armrest from the front door trim.
f. Remove the 8 screws and front door trim pocket from the front door trim.
5. REMOVE LOWER FRAME BRACKET GARNISH
Using a screwdriver, remove the lower frame bracket as shown in the illustration.
HINT: Tape the screwdriver tip before use.
6. REMOVE OUTSIDE REAR VIEW MIRROR
Torque: 7.8 N.m (80 kgf.cm, 69 ft.lbf)
7. REMOVE DOOR SPEAKER BOARD
8. REMOVE INSIDE HANDLE
a. Remove the screw.
b. Slide the inside handle backward to remove it.
c. Disconnect the 2 cables from the inside handle as shown in the illustration.
9. REMOVE SERVICE HOLE COVER
a. Using a clip remover, remove the grommets.
b. Remove the service hole cover.
NOTE: Do not tear the cover.
HINT: At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the service hole cover.
10. REMOVE FRONT DOOR WEATHERSTRIP
a. Using a clip remover, remove the clip.
b. Remove the screw from the door check.
c. Using a clip remover, remove the front door weatherstrip.
d. Reinstall the screw to the door check.
Torque: 25 N.m (260 kgf.cm, 19 ft.lbf)
11. REMOVE FRONT DOOR BELT MOULDING
a. Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched.
b. Using a moulding remover, remove the front door belt moulding.
12. REMOVE FRONT DOOR OUTSIDE LOWER MOULDING
a. Using a drill of less than dia 3.2 mm (0.126 in.), drill out the 3 rivet heads.
HINT: Gently and vertically put the drill to the rivets, and cut the rivet flanges.
CAUTION: Take care as the cut rivets are hot.
NOTE: Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
b. Using a clip remover, remove the clip.
c. Remove the front door outside lower moulding.
d. Using a vacuum cleaner, remove the drilled rivets and associated metallic dust from the inside of door panel.
HINT: At the time of reassembly, please refer to the following item.
Using an air riveter with nose piece No. 1 or a hand riveter with nose piece No. 1 to install new 3 rivets to the front door outside lower moulding.
NOTE:
- At the time of reassembly, please refer to the following items.
- Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
- Do not tilt the riveter disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
- Install the rivet while attaching materials, as they are not tightened firmly.
13. REMOVE NO. 2 SERVICE HOLE COVER
Remove the window regulator connector clamp, 3 screws and No. 2 service hole cover.
14. REMOVE DOOR GLASS
a. Open the door glass until the bolts appear in the service hole.
b. Remove the 2 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
NOTE: Be careful not to drop the door glass.
c. Pull the door glass upward to remove it.
15. REMOVE DOOR GLASS RUN
16. REMOVE WINDOW REGULATOR ASSEMBLY
a. Disconnect the connector, then remove the bolt, 3 nuts and window regulator assembly.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
HINT: Remove the window regulator assembly through the service hole.
b. Using a torx driver, remove the 3 torx screws and window regulator motor from the window regulator guide assembly.
HINT: At the time of reassembly, please refer to the following items.
- Apply MP grease to the glass guide and rollers of window regulator assembly.
- After installing the window regulator assembly, window regulator assembly need to be re-initialized.
17. REMOVE FRONT LOWER FRAME
18. REMOVE REAR LOWER FRAME
19. REMOVE DOOR LOCK
a. Disconnect the 2 control links from the outside handle and door lock cylinder.
b. Disconnect the connector.
c. Remove the 3 torx screws, bolt and door lock.
Torque:
Bolt: 5.4 N.m (55 kgf.cm, 48 in.lbf)
Screw: 4.9 N.m (50 kgf.cm, 43 in.lbf)
HINT: Remove the door lock through the service hole.
HINT: At the time of reassembly, please refer to the following item.
Apply adhesive to 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Remove the 2 screws and door lock protector from the door lock.
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.
20. REMOVE OUTSIDE HANDLE
a. Remove the 2 bolts and outside handle with key cylinder.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
b. Remove the bolt and key cylinder from the outside handle.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
For Power Window Initialization/Reset Programming and Relearning