Removal and Replacement
REMOVAL AND INSTALLATION1. DOOR ASSY
1. Remove lower trim and disconnect connectors from body harness.
2. Place a cloth or a wood block under door to prevent damage, and support it with a jack.
3. Remove checker pin by driving it upward. Be careful not to damage door and body.
4. Remove bolts (M8) securing upper and lower hinges to door, and remove door from hinges.
Tightening torque:
25 ± 3 N.m (2.5 ± 0.3 kg-m, 18.1 ± 2.2 ft-lb)
5. Remove hinges by loosening hinges mounting bolt (M8) off of body.
Tightening torque:
29 ± 5 N.m (3.0 ± 0.5 kg-m, 21.7 ± 3.6 ft-lb)
CAUTION: Work carefully to avoid damaging door.
6. Installation is in the reverse order of removal.
NOTE: Apply grease to moving parts of door hinges.
2. TRIM PANEL
1. Press retainer spring (1) with a thin flat bladed screwdriver and then remove regulator handle (2). (models without power window)
2. Remove gusset cover (1) and three screws.
3. Using ST, disengage the clip.
ST 925580000 PULLER
4. Remove trim panel and then disconnect connector.
(models with power window)
CAUTION: Be careful not to break clip by applying undue force.
Installation is in the reverse order of removal.
3. SEALING COVER
1. Remove trim panel.
2. Remove speaker, remote assembly and disconnect connectors.
3. Remove sealer with a spatula.
CAUTION: Be careful because cover may break if sealer is removed forcefully.
4. Install in reverse order of removal. Some special items will be described.
5. Confirm that sealer is properly applied without breaks. Then install sealing cover.
6. When repairing or replacing sealing cover, use "CEMEDINE 5430L" as sealer. It may be overlaid on existing sealer.
Sealer: CEMEDINE 5430L
CAUTION:
- Any breaks in sealer can cause water leakage or entry of air and dust. Be sure sealer is applied in a continuous line.
- Do not stop up drain hole (1) with sealer.
- Do not stop up install hole (2) with sealing cover.
- Make sure sealing cover bonded areas are free from wrinkles or openings.
4. CHECKER
1. Remove trim panel.
2. Remove sealing cover.
3. Apply a cloth to door and body to prevent damaging them, and remove checker pin by driving it upward.
CAUTION: Be careful not to damage door and body.
4. Completely close door glass.
5. Loosen two nuts securing checker, and take out checker through access hole in underside.
Installation should be made in the reverse order of removal.
Tightening torque:
7.4 ± 2.0 N.m (0.75 ± 0.2 kg-m, 5.4 ± 1.4 ft-lb)
5. DOOR GLASS
1. Remove trim panel.
2. Remove sealing cover.
3. Disconnect door mirror connector and then remove gusset (1).
4. Remove inner remote.
5. Remove inner stabilizer (1).
6. Remove nut and then separate glass holder (1) from guide channel A (2).
NOTE: When removing nut, move door window lower glass connecting section to service hole of door panel.
7. Remove window glass upward.
CAUTION: After removing window glass, do not move regulator.
8. Remove regulator installing bolt and guide channel B installing nut.
9. Remove regulator through lower service hole of door panel.
10. Installation is in the reverse order of removal.
6. INNER REMOTE
1. Remove trim panel.
2. Remove sealing cover.
3. Disconnect joints of two rods.
4. Unlatch rod holder.
5. Remove remote holder (1) and then remove inner remote assembly (2).
6. Installation is in the reverse order of removal. Some special items will be described.
7. After passing two rods through holder, attach remote assembly to inner panel.
8. Latch rod holder.
9. Lock the door and then loosen bolt (1).
10. Lower bell-crank (1) and then tighten bolt (2).
NOTE: If rear door is equipped with child safety lock, check that child lock lever moves without dragging.
7. DOOR LATCH
1. Remove trim panel.
2. Remove inner remote assembly.
3. Remove sealing cover around latch service hole.
4. Completely close door glass.
5. Remove latch and actuator assembly.
1. Turn rod holder to disconnect joint between key lock and rod.
2. Turn rod holder to disconnect joint between outer handle and rod.
3. Turn rod holder to disconnect joint between crank and rod.
6. Loosen screws securing both latch and actuator, then remove latch and actuator assembly through service hole in bottom.
Tightening torque (screw):
6.4 ± 2.0 N.m (0.65 ± 0.2 kg-m, 4.7 ± 1.4 ft-lb)
7. Installation is in the reverse order of removal.
Some special items will be described.
8. Check operation of each part.
9. Check each sliding part for proper lubrication.
CAUTION: After Installation, be sure lock mechanism operates normally.
8. OUTER HANDLE
1. Remove trim panel.
2. Remove sealing cover.
3. Detach door latch rod from outer handle and key lock.
4. Loosen nut securing outer handle and then remove outer handle from outside.
CAUTION: Be careful not to damage door.
Installation is in the reverse order of removal.
Tightening torque:
7.4 ± 2.0 N.m (0.75 ± 0.2 kg-m, 5.4 ± 1.4 ft-lb)
9. KEY LOCK
1. Remove trim panel.
2. Remove sealing cover.
3. Completely close door glass.
4. Remove outer handle.
5. Loosen spring (1) securing key lock.
6. Remove key lock from outer handle.
Installation is in the reverse order of removal.
NOTE: Install so that key slot in key lock comes to center of hole in outer handle.
10. GUSSET
NOTE: Be sure window is all the way down.
1. Remove trim panel.
2. Remove door rearview mirror.
3. Remove sealing cover.
4. Remove bolts and nuts which secure gusset.
5. Lift out gusset (1).
To install, reverse the above removal procedures.