Front Door Disassembly

DOOR / HATCH: FRONT DOOR: DISASSEMBLY; 2013 MY FR-S [03/2012 -]

HINT
Use the same procedure for both the RH and LH sides.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Removal

2. REMOVE DOOR ARMREST COVER

(a) Using a screwdriver with its tip wrapped in protective tape, disengage the 7 claws.

(b) Disengage the guide and remove the door armrest cover.

3. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Using a screwdriver with its tip wrapped in protective tape, open the cap.

(b) Using a clip remover, disengage the clip.

(e) Pull out the front door trim board sub-assembly in the direction indicated by the arrow in the illustration.

(f) Disconnect each connector.

(g) Raise the front door trim board sub-assembly and remove the front door trim board sub-assembly together with the front door glass inner weatherstrip.

(h) Disconnect the front door lock remote control cable and the front door inside locking cable.

4. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Remove the 2 screws.

(b) Disengage the 2 guides and remove the spacer and front door inside handle sub-assembly.

5. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)

(a) Remove the 4 screws and power window regulator master switch assembly with the front door armrest base panel.

6. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)

(a) Remove the 4 screws and power window regulator switch assembly with front door armrest base panel.

7. REMOVE DOOR ASSIST GRIP ASSEMBLY

(a) Remove the 2 screws.

(b) Disengage the guide and remove the door assist grip assembly.

8. REMOVE FRONT LOWER DOOR TRIM PAD

(a) Remove the front lower door trim pad with the 5 screws.

9. REMOVE FRONT DOOR GLASS INNER WEATHERSTRIP

(a) Put a 4 mm (0.1575 in.) drill bit into a drill.

(b) Wind tape around the drill bit approximately 5 mm (0.1969 in.) from the tip of the drill, as shown in the illustration.

HINT
Tape the 4 mm (0.1575 in.) drill bit to prevent the drill bit from going too deep.

(c) Lightly press the drill against the 6 rivets and drill off the flanges of the 6 rivets.

CAUTION:
Take care with the drilled rivet as it may become hot.

NOTICE:
* Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.
* Do not pry the rivet with the drill because this may cause damage to the installation holes of the rivet or the drill bit.

(d) Disengage the 9 claws and remove the front door glass inner weatherstrip from the front door trim board sub-assembly, as shown in the illustration.

10. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY Removal

11. REMOVE FRONT DOOR SERVICE HOLE COVER

(a) Disconnect the outer rear view mirror sub-assembly connector.

(b) Disconnect the front door lock assembly connector.

(c) Remove the front door service hole cover.

HINT
Remove any remaining butyl tape from the door.

12. REMOVE OUTER REAR VIEW MIRROR SUB-ASSEMBLY Removal

13. REMOVE FRONT DOOR WEATHERSTRIP

(a) Disengage the 2 claws and remove the screw.

(b) Using a clip remover, disengage the 15 clips and remove the front door weatherstrip.

14. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY

(a) Provisionally install the power window regulator master switch (for driver side).

(b) Provisionally install the power window regulator switch (for passenger side).

(c) Connect the cable to the negative (-) battery terminal.

(d) Move the front door glass sub-assembly until the 2 nuts can be seen through the service holes.

(e) Disconnect the power window regulator master switch connector (for driver side).

(f) Disconnect the power window regulator switch connector (for passenger side).

(g) Disconnect the cable from the negative (-) battery terminal.

(h) Remove the 3 nuts and loosen the front door rear lower frame sub-assembly.

(i) Remove the 2 nuts.

(j) Loosen the door glass inner stabilizer bolt.

NOTICE:
After the 2 nuts are removed, do not allow the door glass to fall.

(k) While holding the front door glass sub-assembly up, slide the front door rear lower frame sub-assembly downward, and pull the front door glass sub-assembly out from the front door rear lower frame sub-assembly.

NOTICE:
* Do not allow the door glass to fall.
* Do not damage the door glass.

(l) Remove the front door glass sub-assembly from the position indicated in the illustration.

NOTICE:
Do not damage the front door weatherstrip.

HINT
The front glass sub-assembly can only be removed from the position indicated in the illustration.

15. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Remove the front door rear lower frame sub-assembly from the front door frame.

16. REMOVE DOOR GLASS INNER STABILIZER

(a) Remove the bolt and the door glass inner stabilizer.

17. REMOVE FRONT DOOR FIX WINDOW GLASS

(a) Remove the 3 nuts.

(b) Rotate the front door fix window glass as indicated by the arrows in the order shown in the illustration, and remove the front door sash.

NOTICE:
* Since the front door fix window glass attachment bolts interfere, be sure to follow the procedure shown in the illustration.
* Do not allow the front door fix window glass to fall.
* Do not damage the front door sash.

18. REMOVE FRONT DOOR SASH STOPPER

(a) Remove the nut and front door sash stopper.

19. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

(a) Disconnect the connector.

(b) Loosen the temporary bolt.

NOTICE:
Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator sub-assembly may fall and cause damage.

(c) Remove the 3 bolts and 2 nuts.

(d) Remove the temporary bolt and the front door window regulator sub-assembly with power window regulator motor assembly.

20. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY Removal

21. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)

(a) Using a T30 "TORX" socket wrench, loosen the screw and remove the front door lock cylinder assembly with front door outside handle cover LH.

HINT
The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

22. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)

(a) Using a screwdriver, disengage the claw and 2 guides and remove the front door outside handle cover as shown in the illustration.

23. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)

(a) Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.

HINT
The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

24. REMOVE FRONT DOOR LOCK ASSEMBLY Removal

25. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY

(a) Remove the front door outside handle assembly, as shown in the illustration.

26. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Disengage the 3 claws and remove the front door front outside handle pad.

27. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Disengage the 2 claws and remove the front door rear outside handle pad.

28. REMOVE FRONT DOOR LOCK OPEN ROD

(a) Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

29. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Using a T30 "TORX" socket wrench, loosen the screw.

(b) Slide the front door outside handle frame sub-assembly to disengage the claw of the front door outside handle frame sub-assembly, and then remove it.

30. REMOVE FRONT DOOR CHECK ASSEMBLY

(a) Remove the bolt.

(b) Remove the 2 nuts and front door check assembly.

31. REMOVE FRONT DOOR PANEL CUSHION

(a) Disengage the 2 claws and remove the 2 front door panel cushions.

32. REMOVE FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

33. REMOVE DOOR SIDE AIR BAG SENSOR Removal

34. REMOVE FRONT DOOR HOLE COVER

(a) Disengage the 4 claws and remove the front door hole cover.