Front Door: Service and Repair
DISASSEMBLY
1. REMOVE INSIDE HANDLE BEZEL
a. Using a screwdriver, open the screw cap.
HINT: Tape the screwdriver tip before use.
b. Remove the screw.
c. Using a screwdriver, remove the inside handle bezel as shown in the illustration.
HINT: Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
a. Remove the screw.
b. Using a screwdriver, remove the power window switch.
HINT: Tape the screwdriver tip before use.
c. Disconnect the connectors.
3. REMOVE LOWER FRAME BRACKET GARNISH
a. Using a screwdriver, remove the lower frame bracket garnish.
HINT: Tape the screwdriver tip before use.
b. Remove the front flame cover.
4. REMOVE DOOR TRIM
a. Remove the clip.
b. Insert a screwdriver between the door panel and door trim to pry the trim out.
NOTE: Be careful not damage the door panel and trim.
HINT: Tape the screwdriver tip before use.
c. Pull the door trim upward to remove it.
5. REMOVE INSIDE HANDLE
Remove the screw and inside handle, disconnect the 2 cables from the inside handle as shown in the illustration.
6. REMOVE SERVICE HOLE COVER
a. Remove the 2 screws and door trim No. 1 bracket.
b. Remove the 2 grommets.
c. Remove the service hole cover.
NOTE: Do not tear the cover.
HINT: At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the service hole cover.
7. REMOVE SPEAKER
a. Disconnect the connector.
b. Using a drill of less then dia 4 mm (0.16 in), drill out the rivet heads and remove the 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 cafe as the cut rivet is hot.
d. Even if flange is taken off, continue drilling and push out remaining fragments will the drill.
e. Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door.
HINT: At the time of reassembly, please refer to the following item.
Using an air riveter and nose piece No.1, strike rivets into the door panel to install the speaker to the door panel.
NOTE: At the time of reassembly, please refer to the following item.
If the rivet is not positioned perpendicularly it will bend the mandrel. When the trigger is then pulled, it may damage the air riveter.
8. REMOVE OUTSIDE VIEW MIRROR
a. Disconnect the connector.
b. Remove the 3 nuts and outside view mirror.
Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
9. REMOVE DOOR BELT MOULDING Using a scraper, remove the door belt moulding.
HINT: Tape the scraper tip before use.
10. REMOVE DOOR LOCK SILENCER
11. REMOVE DOOR GLASS
a. Remove the 3 bolts and reinforce inside extension.
b. Open the door glass until the door belts appear in the service hole.
c. Remove the 2 bolts.
NOTE: Be careful not to drop the door glass.
d. Pull the door glass upward to remove it.
12. REMOVE DOOR GLASS RUN
13. REMOVE LOWER FLAME
Remove the 2 nuts, plate and lower flame.
14. REMOVE WINDOW REGULATOR
a. Disconnect the connector.
b. Remove the 2 bolts from the window regulator.
Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
c. Remove the 4 bolts and window regulator.
Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf)
HINT: At the time of reassembly, please refer to the following item.
Apply MP grease to the window regulator.
NOTE: At the time of reassembly, please refer to the following item.
Do not apply grease to the spring of the window regulator.
15. REMOVE DOOR LOCK
a. Disconnect the control cable from the clamp.
b. Disconnect the 2 links from the outside handle and key cylinder.
c. Disconnect the connector.
d. Remove the bolt.
Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
e. Remove the 3 screws and door lock.
Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
HINT: At the time of reassembly, please refer to the following item.
Apply adhesive to the 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
Apply grease to the sliding and rotating parts of the door lock.
16. REMOVE OUTSIDE HANDLE
a. Remove the 2 bolts and outside handle.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
b. Remove the key cylinder from the handle.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
For Power Window Initialization/Reset Initialization