Front Door: Service and Repair
DISASSEMBLY1. w/o Power window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag, and remove the regulator handle and plate.
2. REMOVE INSIDE HANDLE BEZEL
a. Remove the screw.
b. Using a screwdriver, pry out the bezel.
HINT: Tape the screwdriver tip before use.
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. w/ Power window:
REMOVE POWER WINDOW SWITCH
Using a screwdriver, remove the power window switch then disconnect the connector.
HINT: Tape the screwdriver tip before use.
5. REMOVE DOOR TRIM BOARD
a. Using a screwdriver, remove the door assist grip cover.
HINT: Tape the screwdriver tip before use.
b. Remove the 2 screws and clip.
c. Insert a screwdriver, between the door panel and door trim board to pry the door trim board loose.
HINT: Tape the screwdriver tip before use.
d. Remove the door trim board.
6. REMOVE DOOR INSIDE HANDLE
a. Remove the screw and inside handle.
b. Disconnect the 2 cables from the inside handle.
7. REMOVE SERVICE HOLE COVER
8. REMOVE FRONT DOOR WEATHERSTRIP
Using a screwdriver, remove the front door weatherstrip.
HINT: Tape the screwdriver tip before use.
9. REMOVE OUTSIDE REAR VIEW MIRROR
a. Disconnect the connector.
b. Remove the 3 bolts and outside rear view mirror.
10. REMOVE DOOR GLASS RUN
11. REMOVE DOOR BELT MOULDING
a. Remove the screw.
b. Using a moulding remover, remove the front door belt moulding.
12. REMOVE DOOR SPEAKER
a. Disconnect the connector.
b. Using a drill of less than Dia 4 mm (0.16 in.), drill out the rivet heads and remove the door speaker.
c. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
- Take care as the cut rivet is hot.
d. Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
e. Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door panel.
13. REMOVE DOOR GLASS
a. Open the door glass until the bolts appear in the service hole.
b. Remove the 2 glass mounting bolts.
NOTE: Be careful not to drop the door glass.
c. Pull up the door glass upward to remove it.
14. REMOVE WINDOW REGULATOR
a. w/o Power window:
Remove the 5 bolts.
b. w/ Power window:
Remove the 6 bolts.
c. w/ Power window:
Disconnect the connector.
d. Remove the regulator through the service hole.
15. REMOVE WINDOW REGULATOR MOTOR
a. Place matchmarks on the window regrator motor bracket and regulator gear.
b. Using a torx wrench, remove the 3 screws and motor.
HINT: At the time of reassembly, please refer to the following item. Align the matchmarks on the regulator motor bracket and regulator gear.
NOTE: If having rotated the motor only, reset the motor.
HINT: Never rotate the motor to the down direction until the complete of the window glass installation.
16. REMOVE DOOR LOCK
a. Disconnect the link from the door lock.
b. Remove the 5 screws and bolt.
c. w/ Power door lock:
Disconnect the connector.
d. Remove the door lock through the service hole.
17. REMOVE OUTSIDE HANDLE
Remove the 2 screws and outside handle.
REASSEMBLY
1. INSTALL OUTSIDE HANDLE
Install the outside handle with the 2 screws.
Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf)
2. INSTALL DOOR LOCK
HINT: Apply MP grease to the sliding surface of the door lock.
a. Install the door lock through the service hole.
b. w/ Power door lock:
Connect the connector.
c. Install the door lock with the 5 screws and bolt.
Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf)
HINT: Apply adhesive to the 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Connect the link to the door lock.
3. INSTALL WINDOW REGULATOR
a. w/ Power window:
Install the motor with the 3 screws.
HINT: Apply MP grease to the window regulator rollers.
b. Install the window regulator through the service hole.
c. w/ Power window:
Install the window regulator with the 6 nuts.
Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf)
d. w/ Power window:
Connect the connector.
e. w/o Power window:
Install the window regulator with the 5 nuts.
Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf)
4. INSTALL DOOR GLASS
Install the door glass with the 2 glass mounting bolts.
Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf)
NOTE: Be careful not to drop the door glass.
5. INSTALL DOOR SPEAKER
a. Using an air riveter or hand riveter, install the door speaker with 3 new rivets.
NOTE:
- Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
- Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
- Install the rivet while attaching materials, as they are not tightened firmly.
b. Connect the connector.
6. INSTALL DOOR BELT MOULDING
7. INSTALL DOOR GLASS RUN
8. INSTALL OUTSIDE REAR VIEW MIRROR
a. Install the outside rear view mirror with the 3 bolts.
b. Connect the connector.
9. INSTALL FRONT DOOR WEATHERSTRIP
10. INSTALL SERVICE HOLE COVER
HINT: Pull out the links through the service hole cover.
11. INSTALL DOOR INSIDE HANDLE
a. Install the door inside handle with the 2 screws.
b. Connect the link to the door inside handle.
12. INSTALL DOOR TRIM BOARD
Install the door trim board with the 2 screws and clip.
13. w/Power window:
INSTALL POWER WINDOW SWITCH
14. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH
15. w/o Power window:
INSTALL REGULATOR HANDLE
Install the regulator handle with the snap ring.
HINT: With door window fully closed, install the plate and the regulator handle with the snap ring as shown.
For Power Window Initialization/Reset Initialization