Front Door: Service and Repair

Front Door Assembly

Parts Location:

Removal

1. Disconnect the battery ground cable.
2. Apply a setting mark on the body side hinge.
3. Remove the door check arm pin.







4. Remove upper and lower hinge bolts.
- Position a wood block under the door for protection and support the door assembly with hands during removal or installation.







5. Remove the door harness connection.
- Pull the door harness grommet out in order to disconnect the harness connection.







6. Remove front door assembly.

Installation

To install, follow the removal steps in the reverse order, noting the following points:

1. Align the door fitting to the body.
- Check the fender and front door (3)

Clearance: 5.0 mm (0.196 in)

Height (step): Flush

- Check the front door and rear door (2).

Clearance: 6.0 mm (0.23 in)

Height (step): Flush

- Check the rear door and body (1) (4).

Clearance: 5.0 mm (0.196 in)

Height (step): Flush

Adjust clearance with door hinges.

Adjust height (step) by tapping on the fender lightly with a rubber hammer.







2. Tighten the door hinge bolts to the specified torque.

Torque: 34 N.m (25 lb ft)

3. Apply chassis grease to the door check arm pin and the door hinge moving surface.