Front Door: Service and Repair

FRONT DOOR

OVERHAUL

HINT:
- Installation is in the reverse order of removal. But, the installation is indicated only when it has a point.
- In the LH side, work in the same procedure as in the RH side.




1. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY
a. Using a screwdriver,disengage the hook, remove the power window regulator master switch assembly then disconnect the connector.

HINT: Tape the screwdriver tip before use.




2. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH
a. Using a screwdriver,disengage the hook, remove the front door lower frame bracket garnish.

HINT: Tape the screwdriver tip before use.




3. REMOVE DOOR PULL HANDLE
a. Using a screwdriver,disengage the hook,remove the door pull handle.

HINT: Tape the screwdriver tip before use.




4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the screw.
b. Using a screwdriver,disengage the hook, remove the door inside handle bezel.




c. Remove the clip and screw.
d. Using a screwdriver, remove the front door trim board.

HINT: Tape the screwdriver tip before use.




5. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY LH
a. Remove the bolt.
b. Remove the inside handle then disconnect the 2 cables from the front door lock assembly.

6. REMOVE FRONT DOOR SERVICE HOLE COVER LH

7. REMOVE FRONT NO.2 SPEAKER ASSEMBLY
a. Disconnect the connector.
b. Remove the bolt and front No.2 speaker assembly.

8. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Remove the 3 bolts.
b. Disconnect the connector then remove the outer rear view mirror assembly.

9. REMOVE FRONT NO.1 SPEAKER ASSEMBLY
a. Remove the 3 bolts.
b. Disconnect the connector then remove the front speaker assembly.

10. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH

11. REMOVE FRONT DOOR GLASS RUN LH

12. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH
a. Remove the bolt and front door frame rear lower.




13. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY LH

HINT: Insert a shop rag inside the door panel to prevent scratching the 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.

HINT: Pull the glass upward to remove it.

14. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Remove the 6 bolts.
b. Disconnect the connector, and then remove the front door window regulator.

15. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx wrench (T25), remove the 3 screws and the motor assembly.

16. APPLY BODY GREASE
a. Apply MP grease to the sliding and rotating parts of the regulator assembly.




17. REMOVE FRONT DOOR LOCK ASSEMBLY LH
a. Disconnect the connector.
b. Disconnect the links from the front door outside handle.
c. Using a torx wrench (T30), remove the 4 screws and front door lock assembly.

18. APPLY BODY GREASE
a. Apply MP grease to the sliding and rotating parts of the door lock.




19. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a torx wrench (T30), remove the 2 screws and door lock cylinder assembly.
b. Pushing the outside handle in the arrow mark direction in the illustration, remove the front outside handle and front outside handle frame.




20. INSTALL FRONT DOOR LOCK ASSEMBLY LH
a. Using a torx wrench (T30), install the front door lock assembly with the 4 screws.

Torque:
A : 5.0 N.m (50 kgf.cm, 45 in.lbf)
B : 5.5 N.m (56 kgf.cm, 49 in.lbf)

b. Install the 2 bolts.
c. Connect the links to the front outside handle.
d. Connect the connector.

21. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. If the jam protection dose not function properly, perform the following procedure.

HINT: It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed.

1. Remove the power window motor.

HINT: Place the matchmarks on the power window motor and window regulator gear.

2. Connect the power window motor and power window switch to the wire harness of the vehicle.
3. Turn the ignition switch ON and operate the power window switch to idle the power window motor in the up side direction for more than 6 rotations or less than 10 rotations (4 seconds or more).
4. Assemble the power window motor and regulator.

HINT:
- Install the motor when the regulator arm is below the middle point.
- Align the match marks on the power window motor and window regulator gear when installing the power window motor.

5. Assemble the power window regulator and door glass.

Torque: 3.9 - 6.9 N.m (39.8 - 70.3 kgf.cm, 35 - 61 in.lbf)

HINT: Never rotate the motor to the down direction until the window glass is completely installed.

22. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Install the front door window regulator with the 6 bolts.

Torque: 11.0 N.m (112 kgf.cm, 8 ft.lbf)

23. INSPECT FUNCTION OF POWER WINDOW Component Tests and General Diagnostics




24. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Install a new 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 installing the service hole cover.
- After installing the service hole cover, check the sealing condition.