Front Door: Service and Repair

Front Door Assembly Removal And Installation

Removal
1. Remove front fender.
2. Disconnect door harness lead wires at each coupler.
3. Remove stopper pin (1).







4. Support door panel using a jack (3) with a piece of wood (2) placed between jack and panel, as shown.







5. Remove door assembly (3) from body (4) by loosening hinge mounting bolts (1, 2).







Installation
Reverse removal procedure to install door assembly, noting the following point.

NOTE:
- When replacing door, coat replacement door inside with wax for proper anticorrosion treatment.
- Refer to Undercoating / Anti-Corrosion Compound Application Area.

- Tighten door hinge bolts (and nut) to specified torque.

Tightening torque
Front door hinge bolt (a): 27 N.m (2.7 kg-m, 19.5 lbf-ft)
Rear door hinge bolt (b): 27 N.m (2.7 kg-m, 19.5 lbf-ft)
Rear door hinge nut (c): 23 N.m (2.3 kg-m, 17.0 lbf-ft)







- Adjust door latch striker position by referring to Canvas Top and Topbow Frames Removal and Installation, Front Door Lock Assembly Removal and Installation so that door is positioned correctly.
- Adjust front door cushion so that door contacts body when closed.
- After installation, open and close the door to check looseness. Replace door open stopper pin when there is looseness.
- When weather-strip is hardened, water leak may develop.
In such case, replace it with new one.