Reassembly

ENGINE HOOD / DOOR: FRONT DOOR: REASSEMBLY

1. REPAIR INSTRUCTION

2. INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

3. INSTALL FRONT DOOR STRIPE

4. INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

5. INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

6. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

7. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 19 clips and install the front door weatherstrip.

8. INSTALL FRONT DOOR CHECK ASSEMBLY (for TMC Made)

(a) Install the front door check assembly with the 3 bolts.

Bolt (A) - Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

Bolt (B) - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

9. INSTALL FRONT DOOR CHECK ASSEMBLY (for TMMK Made)

(a) Install the front door check assembly with the bolt and 2 nuts.

Bolt - Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

Nut - Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

10. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Smart Key System)

(a) Install the door electrical key oscillator with the screw.

11. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Smart Key System)

(a) Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.

(b) Engage the claw to install the front door outside handle frame sub-assembly.

(c) Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

12. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Smart Key System)

(a) Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.

(b) Engage the claw to install the front door outside handle frame sub-assembly.

(c) Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(d) Engage the 2 clamps.

(e) Connect the connector.

13. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Install the front door inside locking cable assembly.

(b) Engage the 3 claws.

14. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

(a) Install the front door lock remote control cable assembly.

15. INSTALL FRONT DOOR LOCK ASSEMBLY

NOTICE:
* When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
* Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
* Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion to the connection. This may result in a malfunction of the front door lock assembly.
(a) Apply MP grease to the sliding parts of the front door lock assembly.

(b) Install a new door lock wiring harness seal to the front door lock assembly.

(c) Insert the front door lock open rod to the front door lock assembly, and set it to the front door outside handle frame.

(d) Make sure that the front door lock open rod is securely connected to the front door lock assembly.

(e) Using a "TORX" socket wrench (T30), install the front door lock assembly with the 3 screws.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(f) Connect the connector.

16. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 2 claws to install the front door rear outside handle pad.

17. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the 3 claws to install the front door front outside handle pad.

18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Smart Key System)

(a) Insert the front end of the front door outside handle assembly into the front door outside handle frame.

(b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Next, slide the front door outside handle assembly toward the front of the vehicle to install it.

19. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Smart Key System)

(a) Insert the front end of the front door outside handle assembly into the front door outside handle frame.

20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER

(a) Engage the 2 claws to install the front door outside handle cover to the front door lock cylinder.

(b) Install the front door lock cylinder.

HINT
Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

(c) Using a "TORX" socket wrench (T30), install the front door lock cylinder with the screw.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(d) Install the hole plug.

21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Install the front door rear lower frame sub-assembly with the bolt.

22. INSTALL FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Install the front door front lower frame sub-assembly with the 2 bolts.

23. INSTALL DOOR FRAME GARNISH

(a) Engage the clip and install a new door frame garnish.

24. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.

25. INSTALL FRONT NO. 1 DOOR STIFFENER CUSHION

(a) Engage the 2 claws and install a new front No. 1 door stiffener cushion with double-sided tape.

26. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTICE:
The regulator arm must be below the intermediate position when installing the power window regulator motor.

(a) Using a "TORX" driver (T25), install the front power window regulator motor sub-assembly with the 3 screws.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

HINT
A new front window regulator adopts a self-tapping method. The installation position of the regulator will be threaded when the self-tapping screw is inserted.

27. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY

(a) Apply MP grease to the sliding parts of the front door window regulator sub-assembly.

(b) Install the temporary bolt to the front door window regulator sub-assembly.

(c) Temporarily install the window regulator.

(d) Tighten the 6 bolts in the order shown in the illustration to install the front window regulator.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

28. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated in the order of the arrows in the illustration.

(b) Install the front door glass sub-assembly with the 2 bolts.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

29. INSTALL FRONT DOOR SERVICE HOLE COVER

(a) Apply butyl tape to the front door panel.

(b) Pass the front door lock remote control cable and rear door inside locking cable through a new front door service hole cover.

(c) Install the new service hole cover.

NOTICE:
Securely install the front door service hole cover avoiding wrinkles and air bubbles.

(d) Connect each connector and each clamp.

30. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY Installation

31. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation

32. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Engage the 4 claws and install the front door inner glass weatherstrip.

33. INSTALL FRONT ARMREST BASE PANEL UPPER

(a) Engage the 4 claws and install the front armrest base panel upper.

(b) Install the 7 screws.

34. INSTALL FRONT DOOR WIRE (for Driver Side)

(a) Install the front door wire with the 2 screws.

(b) Engage the clamp.

35. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY

(a) Connect the connector.

(b) Install the power window regulator master switch assembly with the 3 screws.

36. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle sub-assembly.

(b) Engage the 2 claws and install the front door inside handle sub-assembly.

37. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Connect each connector.

(b) Engage the front door trim board with the 4 clips of the front door inner glass weatherstrip.

(d) Install the 3 screws and clip (A).

38. INSTALL COURTESY LIGHT ASSEMBLY

(a) Connect the connector.

(b) Engage the claw and install the courtesy light assembly.

39. INSTALL ASSIST GRIP COVER

(a) Engage the 6 claws and install the assist grip cover.

40. INSTALL FRONT DOOR INSIDE HANDLE BEZEL PLUG

(a) Engage the 3 claws and install the front door inside handle bezel plug.

41. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Engage the 2 clips and install the front door lower frame bracket garnish.

42. INITIALIZE POWER WINDOW CONTROL SYSTEM Programming and Relearning