Front Door: Service and Repair
Front Door Components:
DISASSEMBLY
1. REMOVE DOOR INSIDE HANDLE BEZEL
a. Using a screwdriver, open the cap.
HINT: Tape the screwdriver tip before use.
b. Remove the screw.
c. Using a screwdriver, remove the inside handle bezel.
HINT: Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
a. Remove the screw.
b. Using a screwdriver, remove the power window switch as shown in the illustration.
HINT: Tape the screwdriver tip before use.
c. Disconnect the connector.
3. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH
Using a screwdriver, remove the front door lower frame bracket garnish.
HINT: Tape the screwdriver tip before use.
4. REMOVE DOOR TRIM
a. Remove the screw cap.
b. Remove the 4 screws.
c. Insert a screwdriver between the door trim and door panel to pry the door trim.
HINT: Tape the screwdriver tip before use.
d. Pull the door trim upward to remove the door trim.
e. w/ Tweeter speaker:
Disconnect the connector.
f. w/ Tweeter speaker:
Remove the 2 screws and tweeter speaker from the door trim.
g. Remove the 2 screws and door armrest base from the door trim.
5. REMOVE INSIDE HANDLE
Remove the screw and inside handle, then disconnect the 2 cables from the inside handle.
6. REMOVE SPEAKER
a. Remove the 3 screws and speaker.
b. Disconnect the connector.
7. REMOVE SERVICE HOLE COVER
a. Remove the connector clamps.
b. Remove a grommet.
c. Disconnect the connector.
d. Remove the service hole cover.
8. REMOVE OUTSIDE REAR VIEW MIRROR
a. Disconnect the connector.
b. Remove the 3 nuts and outside rear view mirror.
9. REMOVE WEATHERSTRIP
Remove the 4 clips and weatherstrip.
10. REMOVE DOOR SIDE AIRBAG SENSOR
a. Disconnect the connector.
NOTE: Disconnect the connector with the door side airbag sensor installed.
b. Remove the 2 bolts and door side airbag sensor.
11. REMOVE DOOR WINDOW UPPER STOPS
Remove the 2 bolts and 2 door window upper stops.
12. REMOVE DOOR BELT MOULDING
a. Remove a clip.
b. Using a scraper, remove the door belt moulding as shown in the illustration.
HINT: Tape the scraper tip before use.
13. REMOVE DOOR GLASS FEMALE STABILIZER
Remove the screw and door glass female stabilizer.
14. REMOVE DOOR GLASS
HINT: Insert a shop rag inside the door panel to prevent scratching the glass.
a. Open the door glass until the nuts appear in the service hole.
b. Remove the 3 nuts and door glass.
NOTE: Do not damage the door glass.
HINT: Pull the glass upward to remove it.
15. REMOVE WINDOW REGULATOR ASSEMBLY
a. Remove the 7 nuts and window regulator assembly.
HINT: Remove the window regulator assembly through the service hole.
b. Disconnect the connector.
16. If replacing the window regulator:
REMOVE WINDOW REGULATOR FROM MOTOR
a. Remove the 2 screws and cover plate.
b. Using a needle nose pliers, remove the drum and wire guide from the motor.
NOTE: Do not use a screwdriver etc. to help remove them.
17. REMOVE FRONT LOWER FRAME
a. Remove the 2 bolts and nut.
b. Pull the front lower frame upward.
c. Rotate the front lower frame 9O ° and pull it upward as shown in the illustration.
18. REMOVE DOOR LOCK
a. Disconnect the 2 links from the outside handle and key cylinder.
b. Remove the nut.
c. Remove the 3 torx screws and door lock.
d. Disconnect the connector.
HINT: Remove the door lock through the service hole.
19. REMOVE OUTSIDE HANDLE AND KEY CYLINDER
a. Remove the hole covers.
b. Remove the 3 bolts and outside handle with the key cylinder.
c. Remove the bolt and key cylinder from the outside handle.
20. REMOVE CUSHIONS
REASSEMBLY
1. INSTALL CUSHIONS
2. INSTALL OUTSIDE HANDLE AND KEY CYLINDER
a. Install the key cylinder with the bolt to the outside handle.
b. Install the outside handle with the key cylinder to the door panel with the 3 bolts and hole covers.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
3. INSTALL DOOR LOCK
HINT: Apply MP grease to the sliding surface of the door lock as shown in the illustration.
a. Connect the connector.
b. Install the door lock with the 3 torx screws.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
HINT: Apply adhesive to the 3 torx screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent.
c. Install the nut.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
d. Connect the 2 links to the outside handle and key cylinder.
4. INSTALL FRONT LOWER FRAME
a. Insert the front lower frame to the door panel, then rotate it 90°.
b. Install the front lower frame with the 2 bolts and nut.
Torque:
Bolt: 8.0 N.m (82 kgf.cm, 71 in.lbf)
Nut: 13 N.m (133 kgf.cm, 10 ft.lbf)
5. If replacing the window regulator:
INSTALL WINDOW REGULATOR TO MOTOR
NOTE:
- To prevent the drum and cable from coming off, do not tilt the drum, subject it to shocks or use force on it.
- If the cable comes off the drum, do not rewind the cable and do not reuse it.
- After installing the window regulator, do not operate it by itself as some types of regulator do not have a stopper.
a. With the holding tool installed, match the holding tool with the motor housing.
b. Push down on the wire guide and drum, and insert the drum into the motor housing.
NOTE: If you can not insert the drum into the motor, slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.
c. Install the cover plate with the 2 screws.
6. INSTALL WINDOW REGULATOR ASSEMBLY
a. Connect the connector.
b. Install the window regulator and shims with the 7 nuts through the service hole.
Torque:
Nut (Upper side): 8.0 N.m (82 kgf.cm, 71 in.lbf)
Nut (Lower side): 13 N.m (133 kgf.cm, 10 ft.lbf)
Motor set nut: 5.0 N.m (51 kgf.cm, 44 in.lbf)
7. INSTALL DOOR GLASS
NOTE: Do not damage the door glass.
HINT: Insert a shop rag inside the door panel to prevent scratching the glass.
a. Put the door glass in the door panel carefully.
b. Install the door glass with the 3 nuts to the window regulator.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
8. INSTALL DOOR GLASS FEMALE STABILIZER
Install the door glass female stabilizer with the screw.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
9. INSTALL DOOR BELT MOULDING
Install the door belt moulding with the clip.
10. INSTALL DOOR WINDOW UPPER STOPS
Install the 2 door window upper stops with the 2 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
11. INSTALL DOOR SIDE AIRBAG SENSOR
a. Install the door side airbag sensor with the 2 bolts.
Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
b. Connect the connector.
NOTE: Connect the connector with the door side airbag sensor installed.
12. INSTALL WEATHERSTRIP
Install the weatherstrip with the 4 clips.
13. INSTALL OUTSIDE REAR VIEW MIRROR
a. Install the outside rear view mirror with the 3 nuts.
b. Connect the connector.
14. INSTALL SERVICE HOLE COVER
a. Install the service hole cover to the door panel.
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, sealing condition shall be confirmed.
b. Connect the connector.
c. Install the grommet.
d. Install the connector clamps.
15. INSTALL SPEAKER
a. Connect the connector.
b. Install the speaker with the 3 screws.
16. INSTALL INSIDE HANDLE
Connect the 2 cables, then install the inside handle with the screw.
NOTE:
- When connecting cable ends to the handle and lock knob, connect them with both door lock and inside handle in unlock position.
- When clamping a cable, ensure that the cable is not loose or broken.
17. INSTALL DOOR TRIM
a. Install the door armrest base with the 2 screws to the door trim.
b. w/ Tweeter speaker:
Install the tweeter speaker with the 2 screws to the door trim.
c. w/ Tweeter speaker:
Connect the connector.
d. Install the door trim with the 4 screws.
e. Install the screw cap.
18. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
Install the front door lower frame bracket garnish.
19. INSTALL POWER WINDOW SWITCH
a. Connect the connector.
b. Install the power window switch with the screw.
20. INSTALL DOOR INSIDE HANDLE BEZEL
a. Install the door inside handle bezel with the screw.
b. Close the cap.