Front Door: Service and Repair

FRONT DOOR DISASSEMBLY





1. (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. Using a screwdriver, pry out the bezel.

HINT: Tape the screwdriver tip before use.

b. Pull the bezel rearwards to remove it.





3. (W/O Power Window):
REMOVE ARMREST PANEL
Using a screwdriver, remove the armrest panel.

HINT: Tape the screwdriver tip before use.





4. (W/ Power Window):
REMOVE DOOR COURTESY LIGHT
Remove the light by pulling, then disconnect the connector.

5. REMOVE DOOR TRIM
(W/ Power Window)

HINT: Tape the screwdriver tip before use.





a. Remove two clips.
b. Using a screwdriver. remove two screw caps and the upper speaker cover.
c. Remove six screws.
d. Insert the screwdriver between the door and the door trim to pry out.
e. Pull the trim upwards to remove it, then disconnect the connectors.





f. Remove the inner weatherstrip.
g. Remove two screws and the power window switch.
h. Remove six screws and the armrest.
i. Remove two screws and the lower speaker cover.
j. Remove the clip, nine screws and the door pocket.





(W/O Power Window)

HINT: Tape the screwdriver tip before use.

a. Remove two clips.
b. Using a screwdriver, remove four screw caps.
c. Remove six screws.
d. Insert the screwdriver between the door and door trim to pry out.
e. Pull the trim upwards to remove it.





f. Remove the inner weatherstrip.
g. Remove four screws and the armrest.
h. Remove two screws and the speaker cover.
i. Remove the clip, ten screws and the door pocket.





6. REMOVE REAR VIEW MIRROR
a. Remove the cover.
b. Remove three screws and the mirror.
c. (W/ Remote Control Mirror) Disconnect the connector.





7. REMOVE DOOR INSIDE HANDLE
a. Disconnect two links.
b. Remove three screws and the handle.





8. REMOVE SPEAKER
a. Remove four screws and the speaker.
b. Disconnect the connector.





9. REMOVE SERVICE HOLE COVER
a. Using a clip remover, remove six screw grommets.
b. Remove service hole cover.

10. REMOVE DOOR GLASS RUN
Pull the glass run upwards to remove it.





11. REMOVE FRONT DOOR BELT MOULDING
Pry out the dips from the edge of the weatherstrip and remove the moulding.

12. REMOVE FRONT DOOR FRAME MOULDING
a. Remove three screws and the nut.
b. Pry out the clips and remove the moulding.

13. REMOVE FRONT DOOR UPPER MOULDING
a. Remove seven screws.
b. Pry out the clip and remove the moulding.





14. REMOVE DOOR GLASS

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

a. Remove two glass mounting bolts.
b. Remove the door glass by pulling it upwards.

15. REMOVE FRONT DOOR WEATHERSTRIP
While pulling the weatherstrip by hand, remove the clips using a clip remover.

HINT: Do not pull strongly on the weatherstrip as it may tear.





16. REMOVE DOOR INSIDE PANEL FRAME
a. Remove four nuts.
b. Remove three bolts and the frame.





17. REMOVE WINDOW REGULATOR
a. Remove two nuts.
b. (W/ Power Window) Disconnect the connector.
c. Remove the regulator through the service hole.





18. REMOVE FRONT LOWER FRAME
Remove the nut, two bolts and the frame.

19. REMOVE REAR LOWER FRAME
Remove the nut, the screw and the frame.





20. REMOVE DOOR LOCK
a. Remove two clips.
b. Disconnect two links from the door lock and remove two links.
c. Disconnect two links from the outside handle and the lock cylinder.
d. Remove three screws.
e. (W/ Power Door Lock) Disconnect the connector.
f. Remove the door lock through the service hole.





21. REMOVE OUTSIDE HANDLE
a. Remove the hole plug.
b. Remove two bolts and the outside handle with the lock cylinder.





22. REMOVE DOOR LOCK CYLINDER
Remove the bolt and the lock cylinder from the outside handle.

FRONT DOOR ASSEMBLY
1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE





a. Apply MP grease to the window regulator rollers.





b. Apply MP grease to the sliding surface of the door lock.





2. INSTALL DOOR LOCK CYLINDER
Install the lock cylinder with the bolt to the outside handle.





3. INSTALL OUTSIDE HANDLE
a. Install the outside handle with two bolts.
b. Install hole plug.





4. INSTALL DOOR LOCK
a. Apply adhesive to three screws. Part No.08833-00070. THREE BOND 1324 or equivalent
b. Install the door lock with three screws.

Torque: 5.4 N.m (55 kgf.cm. 48 in.lbf)

c. (W/ Power Door Lock) Connect the connector.
d. Connect two links to the outside handle and the door lock cylinder.
e. Connect two links to the door lock.
f. Install two clips.





5. INSTALL FRONT LOWER FRAME
Install the frame with the nut and two bolts.

6. INSTALL REAR LOWER FRAME
Install the frame with the nut and the screw.





7. INSTALL WINDOW REGULATOR
a. Place the regulator through the service hole.
b. (W/ Power Window) Connect the connector.
c. Install the regulator with two nuts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)





8. INSTALL DOOR INSIDE PANEL FRAME
a. Install the frame with three bolts.
b. Install four nuts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)

9. INSTALL FRONT DOOR WEATHERSTRIP
Push down on the clips of the weatherstrip.





10. INSTALL DOOR GLASS

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

a. Insert the glass to the frame.
b. Temporarily tighten two glass mounting bolts.





11. INSTALL FRONT DOOR UPPER MOULDING
Install the moulding with seven screws.

12. INSTALL FRONT DOOR FRAME MOULDING
Install the moulding with three screws and the nut.

13. INSTALL FRONT DOOR BELT MOULDING
Install the clan of the clips into the upper panel slit and push the moulding onto the panel.

14. INSTALL DOOR GLASS RUN
Insert the glass run to the door frame.





15. ADJUST DOOR GLASS
Adjust the glass and tighten if where dimension A and B, as shown are equal.

HINT: Substitute the bolt with washer for the centering bolt.





16. INSTALL SERVICE HOLE COVER
a. Seal the service hole cover with adhesive.

HINT: Bring out the links through the service hole cover.

b. Install six screw grommets.





17. INSTALL DOOR INSIDE HANDLE.
a. Install the handle with three screws.
b. Connect two links.

18. INSTALL SPEAKER
Install the speaker with four screws. then connect the connector.





19. INSTALL REAR VIEW MIRROR
a. (W/ Remote Control Mirror) Connect the connector.
b. Install the mirror with three screws.
c. Install the cover.

20. INSTALL DOOR TRIM
(W/ Power Window)





a. Install the door pocket with the clip and nine screws.
b. Install the lower speaker cover with two screws.
c. Install the armrest with six screws.
d. Install the power window switch with two screws.
e. Install the inner weatherstrip.





f. Insert the upper edge of the trim from above, tap the trim by hand fix it in place with the clips, then connect the connectors.
g. Install six screws.
h. Install two screw caps and the upper speaker cover.
i. Install two clips.





(W/O Power Window)
a. Install the door pocket with the clip and ten screws.
b. Install the speaker cover with two screws.
c. Install the armrest with four screws.
d. Install the inner weatherstrip.





e. Insert the upper edge of the trim from above, tap the trim by hand fix it in place with the clips.
f. Install six screws.
g. Install four screw caps.
h. Install two clips.

21. (W/ Power Window)
INSTALL DOOR COURTESY LIGHT
Tap the light to install it, then connect the connector.





22. (W/O Power Window)
INSTALL ARMREST PANEL
Tap the armrest panel to install it.





23. INSTALL INSIDE HANDLE BEZEL
Tap the bezel to install it.





24. INSTALL REGULATOR HANDLE
With door window fully closed, install the plate and the regulator handle with the snap ring as shown.