Front Door: Service and Repair

DISASSEMBLY




1. w/o Power window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a cloth and remove the regulator handle and plate.

2. REMOVE INSIDE HANDLE BEZEL




a. Remove the screw.
b. Using a screwdriver, remove the inside handle bezel as shown in the illustration.

HINT: Tape the screwdriver tip before use.

3. w/ Power window:
REMOVE POWER WINDOW SWITCH




a. Using a screwdriver, remove the power window switch.

HINT: Tape the screwdriver tip before use.

b. Disconnect the connectors.

4. w/ Courtesy light:
REMOVE COURTESY LIGHT
a. Using a screwdriver, remove the courtesy light.

HINT: Tape the screwdriver tip before use.

b. Disconnect the connector.

5. w/o Courtesy light:
REMOVE COURTESY LIGHT COVER
a. Using a screwdriver, remove the courtesy light cover.

HINT: Tape the screwdriver tip before use.

6. w/ Tweeter speaker:
REMOVE TWEETER SPEAKER
a. Using a screwdriver, remove the tweeter speaker cover.

HINT: Tape the screwdriver tip before use.

b. Disconnect the connector.
c. Remove the 3 screws and tweeter speaker.

7. REMOVE DOOR TRIM




a. Remove the 2 caps and 2 screws.
b. Insert a screwdriver between the door trim and door panel to remove the door trim.

HINT: Tape the screwdriver tip before use.

c. Pull the door trim upward to remove it.

8. REMOVE DOOR ASSIST GRIP
Remove the 2 screws and door assist grip from the door trim.

9. REMOVE INNER WEATHERSTRIP
10. REMOVE LOWER WEATHERSTRIP
11. REMOVE INSIDE HANDLE
a. Remove the screw.
b. Slide the inside handle backward to remove it.




c. Disconnect the 2 cables from the inside handle as shown in the illustration.

12. REMOVE SERVICE HOLE COVER
a. Disconnect the clamps and connector.
b. Remove the service hole cover.

13. REMOVE SPEAKER
a. Disconnect the connector.
b. Remove the 3 screws and speaker.

14. REMOVE OUTSIDE REAR VIEW MIRROR
a. w/ Remote control:
Disconnect the connector.

b. Remove the 3 screws and outside rear view mirror.




15. REMOVE DOOR BELT MOULDING
Using a scraper, remove the door belt moulding.

HINT: Tape the scraper tip before use.

16. REMOVE DOOR GLASS RUN




17. REMOVE FRONT LOWER FRAME
Remove the 2 bolts, nut and front lower frame as shown in the illustration.




18. REMOVE REAR LOWER FRAME
Remove the bolt, nut and rear lower frame as shown in the illustration.

19. REMOVE DOOR GLASS




a. Open the door glass until the bolts appear in the service hole.
b. Remove the 2 bolts and door glass.

NOTE: Do not damage the door glass.

20. REMOVE WINDOW REGULATOR




a. w/ Power window:
Disconnect the connector.

b. w/ Power window:
Remove the 5 bolts, nut and window regulator.

c. w/o Power window:
Remove the 4 bolts, nut and window regulator.

d. Remove the window regulator through the service hole.

21. REMOVE DOOR LOCK




a. Disconnect the 2 links from outside handle and door lock cylinder.
b. w/ Power door lock:
Disconnect the connector and remove the bolt.

c. Using a torx socket wrench, remove the 3 torx screws.

Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool)

22. REMOVE OUTSIDE HANDLE WITH DOOR LOCK CYLINDER
a. Remove the 2 bolts and outside handle with door lock cylinder.
b. Remove the door lock cylinder from the outside handle.

REASSEMBLY

1. INSTALL OUTSIDE HANDLE WITH DOOR LOCK CYLINDER
a. Install the door lock cylinder to the outside handle.
b. Install the outside handle with door lock cylinder with the 2 bolts.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)




2. INSTALL DOOR LOCK

HINT: Apply MP grease to the sliding and rotating parts of the door lock.




a. Using a torx socket wrench, install the door lock with the 3 torx screws.

Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool)

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

HINT: Apply adhesive to the 3 screws.

Part No. 08833-00070, THREE BOND 1324 or equivalent

b. w/ Power door lock:
Connect the connector and install the bolt.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

c. Connect the 2 links to the outside handle and door lock cylinder.

3. INSTALL WINDOW REGULATOR

HINT: Apply MP grease to the sliding and rotating parts of the window regulator.




a. Install the window regulator through the service hole.




b. w/ Power window:
Install the window regulator with the 5 bolts and nut.

Torque:
Bolt: 5.0 N.m (51 kgf.cm, 44 in.lbf)
Nut: 5.0 N.m (51 kgf.cm, 44 in.lbf)

HINT: When installing the window regulator, torque the bolts and nut in the order shown in the illustration.

c. w/o Power window:
Install the window regulator with the 4 bolts and nut.

Torque:
Bolt: 5.0 N.m (51 kgf.cm, 44 in.lbf)
Nut: 5.0 N.m (51 kgf.cm, 44 in.lbf)

HINT: When installing the window regulator, torque the bolts and nut in the order shown in the illustration.

d. w/ Power window:
Connect the connector.




4. INSTALL REAR LOWER FRAME
Install the rear lower frame with the bolt and nut.




5. INSTALL FRONT LOWER FRAME
Install the front lower frame with the 2 bolts and nut.

6. INSTALL DOOR GLASS RUN




7. INSTALL DOOR GLASS

NOTE: Do not damage the door glass.

Install the door glass with the 2 bolts.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

8. INSTALL DOOR BELT MOULDING
9. INSTALL OUTSIDE REAR VIEW MIRROR
a. Install the outside rear view mirror with the 3 screws.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

b. w/ Remote control:
Connect the connector.

10. INSTALL SPEAKER
a. Install the speaker with the 3 screws.
b. Connect the connector.

11. INSTALL SERVICE HOLE COVER




a. Install the service hole cover.

HINT:
- When installing the service hole cover, pull out the cables 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 cove, sealing condition shall be confirmed.

b. Connect the clamps and connector.

12. INSTALL INSIDE HANDLE




a. Connect the 2 cables to the inside handle.
b. Slide the inside handle forward to install it.
c. Install the screw.

13. INSTALL DOOR ASSIST GRIP
Install the door assist grip with the 2 screws to the door trim.

14. INSTALL LOWER WEATHERSTRIP
15. INSTALL INNER WEATHERSTRIP




16. INSTALL DOOR TRIM
Install the door trim with the 2 screws and 2 caps.

17. w/ Tweeter speaker:
INSTALL TWEETER SPEAKER
a. Install the tweeter speaker with the 3 screws, then connect the connector.
b. Install the tweeter speaker cover.

18. w/ Courtesy light:
INSTALL COURTESY LIGHT
a. Connect the connector.
b. Install the courtesy light.

19. w/o Courtesy light:
INSTALL COURTESY LIGHT COVER

20. w/ Power window:
INSTALL POWER WINDOW SWITCH




a. Connect the connectors.
b. Install the power window switch.

21. INSTALL INSIDE HANDLE BEZEL
Install the inside handle bezel with the screw.




22. w/o Power window:
INSTALL REGULATOR HANDLE
Install the regulator handle with the snap ring.

HINT: With the door window fully closed, install the plate and the regulator handle with the snap ring as shown in the illustration.