Front Door: Service and Repair
FRONT DOOROVERHAUL
HINT:
- The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
- Use the same procedures on the RH side as on the LH side.
1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
a. Using a screwdriver, disengage the 2 claws and 2 clips, and disconnect the master switch.
HINT: Tape the screwdriver tip before use.
b. Disconnect the master switch connector.
c. Remove the 3 screws and master switch.
2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Using a screwdriver, disengage the 2 clips and claw, and remove the lower frame bracket garnish.
HINT: Tape the screwdriver tip before use.
3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH
a. Using a screwdriver, disengage the 3 claws and remove the inside handle bezel.
HINT: Tape the screwdriver tip before use.
4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the door armrest cover.
b. Remove the 2 screws and clip A indicated in the illustration.
c. Using a screwdriver, disengage other 11 clips.
d. Remove the trim board.
HINT:
- In order to prevent the door panel from being damaged, cover the areas indicated by arrow marks in the illustration with protective tape.
- Tape the screwdriver tip before use.
e. Disconnect the 2 cables from the inside handle.
f. Disengage the connectors and remove the trim board.
g. Using a screwdriver, disengage the claw and, remove the lamp in the direction indicated by arrow marks in the illustration.
HINT: Tape the screwdriver tip before use.
5. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH
a. Remove the weatherstrip inner by pulling it upward in the direction indicated by arrow mark in the illustration.
6. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Disconnect the mirror connector.
b. Remove the 3 bolts and mirror.
NOTE: When the nuts are removed, the mirror may fall and become deformed.
7. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH
8. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH
9. REMOVE FRONT DOOR ARMREST SET BRACKET LH
a. Remove the 2 screws and armrest set bracket.
10. REMOVE FRONT DOOR SERVICE HOLE COVER LH
NOTE: Remove the remaining tape on the door side.
11. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
12. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH
HINT: Insert a shop rag inside the door panel to prevent the door glass from being scratched.
a. Open the door glass until the bolts appear in the service holes.
b. Remove the 2 bolts holding the door glass to the window regulator.
c. Remove the door glass in the direction indicated by arrows in the illustration.
NOTE:
- Do not damage the door glass.
- When the bolts are removed, the door glass may fall and become deformed.
d. Remove the glass run.
13. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Remove the 6 bolts and window regulator.
NOTE: When the bolts are removed, the window regulator may fall and become deformed.
HINT: Remove the window regulator through the service hole.
14. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Place matchmarks on the regulator motor gear and regulator gear.
b. Using a torx driver (T25), remove the 3 screws and window regulator motor.
15. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Remove the bolt and frame.
HINT: Remove the frame through the service hole.
16. REMOVE FRONT DOOR OUTSIDE HANDLE COVER
a. Remove the hole plug.
b. Using a torx socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.
17. REMOVE FRONT DOOR LOCK ASSEMBLY LH
a. Disconnect the lock connector.
b. Using a torx socket wrench (T30), remove the 3 screws and door lock.
HINT: Remove the door lock through the service hole.
18. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH
a. Pushing and pulling the handle in the direction indicated by arrow mark in the illustration, remove the handle.
b. Remove the outside handle pads front and rear.
19. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a torx socket wrench (T30), loosen the screw.
b. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration and remove it.
HINT: Remove the outside handle frame through the service hole.
c. Remove the lock open rod from the outside handle frame.
20. REMOVE FRONT DOOR CHECK ASSEMBLY LH
a. Remove the check cover.
b. Remove the 2 nuts, bolt and door check.
21. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clips and remove the weatherstrip.
HINT: If the clips are damaged, exchange them for new clips.
22. 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: 8 Nm (82 kgf.cm, 71 in.lbf)
HINT: Install the door check so that the rivet head is up.
c. Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install the door check to the body with the bolt.
Torque: 27 Nm (275 kgf.cm, 20 in.lbf)
e. Install the check cover.
23. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Install the lock open rod to the handle frame.
b. Slide the handle frame in the direction indicated by the arrow mark in the illustration.
c. Using a torx socket wrench (T30), install the outside handle frame with the screw.
Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)
NOTE: Insert a cover between the nut and the door panel.
d. Install the outside handle pads front and rear.
24. 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.
NOTE:
- If reusing a door lock that has been removed, replace the packing in the connecting part with a new packing.
- Be careful that no grease and dirt sticks to the packing surface in the connecting part.
- Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.
c. Insert the door lock open rod into the door lock and then set it to the door panel.
NOTE: Make sure that the outside handle link is securely engaged with the door lock.
d. Apply adhesive to the threads of the screws.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
e. Using a torx socket wrench (T30), install the door lock with the 3 screws.
Torque: 5.0 Nm (51 kgf.cm, 42 in.lbf)
f. Connect the door lock connector.
25. INSTALL FRONT DOOR OUTSIDE HANDLE COVER
a. Using a torx socket wrench (T30), install the outside handle cover with the screw.
Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)
b. Install the hole plug.
26. INSTALL FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Install the door frame with the bolt.
Torque: 5.0 Nm (51 kgf.cm, 42 in.lbf)
27. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Align the matchmarks on the regulator motor gear and regulator gear.
b. Using a torx driver (T25), install the regulator motor with the 3 screws.
Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf)
HINT: Never rotate the motor to the down direction until the window glass installation is done.
28. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the window regulator.
NOTE: Do not apply grease to the spring of the window regulator.
b. Install the window regulator with the 6 bolts in the order as shown in the illustration.
Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)
c. Connect the window regulator connector.
NOTE: Be careful not to drop the door window regulator as this may cause deformation.
29. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH
NOTE: Do not damage the door glass.
a. Install the glass run.
b. Insert the door glass into the door panel along the glass run in the direction indicated by the arrow mark 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. Reset the power window motor.
e. Inspect operation of the power window.
HINT: When the installation point of the door glass does not match, adjust the regulator position in manual operation.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Repeat UP and DOWN operation several times in manual operation.
30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Install the mirror with the 3 bolts.
Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)
b. Connect the mirror connector.
31. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door panel, as shown in the illustration.
b. Install the 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, confirm the sealing condition.
For Power Window Initialization/Reset [1][2]Programming and Relearning