Front Door: Service and Repair

Front Door

Removal





1
NOTE:
The front door is manufactured from mild steel, it contains a side impact reinforcement manufactured from boron steel.
The front door is serviced as a separate bolt-on panel.
2 For additional information relating to this repair procedure please see the following: For additional information, refer to Health and Safety Precautions Health and Safety Precautions
For additional information, refer to Body Repairs
For additional information, refer to Corrosion Protection
For additional information, refer to Body and Frame
3
NOTE:
If the procedure includes removal of the front door components, the battery can remain connected to aid their removal and disconnected afterwards.
Disconnect the battery ground cable. For additional information, refer to Battery Disconnect and Connect Battery Disconnect and Connect
4
NOTE:
For new front door installation, this step may be carried out later in the removal procedure.
Disconnect the front door wiring harness, accessed behind the grommet on the A-pillar.
5
NOTE:
For new front door installation, this step may be carried out later in the removal procedure.
Release the front door check strap from the body.




6
NOTE:
This step is for removing the fully trimmed front door for access only, for installing a new front door, continue to removal step 7.
Remove the front door upper and lower hinge pivot bolts and lift the front door to remove.
7 Remove the front door window regulator and motor. For additional information, refer to Front Door Window Regulator and Motor Front Door Window Regulator and Motor
8 Remove the exterior mirror. For additional information, refer to Exterior Mirror Exterior Mirror
9 Remove the front door latch. For additional information, refer to Front Door Latch Service and Repair

10 Remove the front door outer window frame mouldings.

11 Remove the front door weatherstrips.

12 Remove the front door wiring harness.

13 Remove the front door impact absorbers.

14 Remove the front door check strap.

15 Remove the front door glass run felt.

16 Remove any miscellaneous front door clips, grommets and blanking covers.





17
NOTE:
If new hinges are being installed, install the complete hinges to the A-pillar. To align the hinges at the A-pillar it will be necessary to remove the front fender.
Remove the upper and lower front door hinge fixing bolts and remove the front door.

Installation
1
NOTE:
If the front door has been removed for access only, it can be installed back on to its upper and lower hinge pivots and secured with the upper and lower hinge pivot bolts.
Offer up the front door and loosely install the front door hinge bolts.
2 Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.
3 Tighten the front door hinge bolts to 30 Nm.




4 When correctly aligned and with the front door hinge bolts tightened, the new front door can be removed at its upper and lower hinge pivot bolts for refinishing.
5
NOTE:
Install the front door upper frame weatherstrip prior to installing the front door.
The installation of associated panels and components is the reversal of removal procedure.
- Tighten the front door upper and lower hinge pivot bolts to 30 Nm.