Front Door: Service and Repair
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.
HINT: At the time of reassembly, please refer to the following item.
With door window fully closed, install the plate and the regulator handle with the snap ring.
2. w/ Power window:
REMOVE POWER WINDOW SWITCH
a. Using a screwdriver, remove the power window switch.
HINT: Tape the screwdriver tip before use.
b. Disconnect the connector.
3. REMOVE LOWER FRAME BRACKET GARNISH
4. REMOVE DOOR TRIM
a. Remove the screw and pull handle.
b. 2-Door vehicle:
Remove the screw and 2 clips.
c. 4-Door vehicle:
Remove the screw and 3 clips.
d. Insert a screwdriver between the door panel and door trim to pry the trim out.
NOTE: Be careful not to damage the door panel and trim.
HINT: Tape the screwdriver tip before use.
e. Pull the door trim upward to remove it.
f. Remove the door lock control knob holder.
5. REMOVE INNER WEATHERSTRIP
Remove the inner weatherstrip as shown in the illustration.
6. REMOVE OUTSIDE REAR VIEW MIRROR
a. w/ Power remote control mirror:
Disconnect the connector.
b. Remove the 3 nuts and rear view mirror.
Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
7. REMOVE DOOR INSIDE HANDLE
a. Remove the door inside handle in order A, B as shown in the illustration.
b. Disconnect the door lock cable from the door inside handle.
8. REMOVE PULL HANDLE BRACKET
Remove the 2 screws and pull handle bracket.
9. REMOVE SERVICE HOLE COVER
Remove the service hole cover.
HINT: At the time of reassembly, please refer to the following item.
Bring out the cable through the service hole cover.
10. REMOVE NO. 1 STIFFENER CUSHION
11. w/ Door speaker:
REMOVE DOOR SPEAKER
a. Using a drill of less then dia 4.8 mm (0.189 in.), drill out the rivet heads and remove the speaker.
b. Disconnect the connector.
c. Using a vacuum cleaner, remove the drilled rivets and their dust from the inside of the door panel.
CAUTION: The cut rivet and rivet cutter will be hot, avoid touching them.
NOTE:
- Do not jiggle the rivet cutter while cutting.
- You may enlarge the rivet hole or damage the rivet cutter.
HINT: Do not drill the door inner hole.
HINT: At the time of reassembly, please refer to the following item.
Using an air riveter, 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.
12. REMOVE DOOR GLASS
a. Open the door glass until the bolts appear in the service hole.
b. Remove the 2 bolts.
NOTE: Be careful not to drop the door glass.
c. Pull the door glass upward to remove it.
13. REMOVE WINDOW REGULATOR
a. w/ Power window:
Disconnect the connector.
b. w/ Power window:
Remove the 6 bolts and window regulator.
Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf)
c. w/o Power window:
Remove the 5 bolts and window regulator.
Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf)
HINT:
- Remove the regulator through the service hole.
- 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.
14. REMOVE DOOR BELT MOULDING
Using a scraper, remove the door belt moulding.
HINT: Tape the scraper tip before use.
15. REMOVE DOOR GLASS RUN
a. Remove the clip and door glass run.
b. Remove the 2 glass stops.
HINT: Pull the glass run upward.
16. REMOVE FRONT AND REAR LOWER FRAMES
Remove the 2 bolts and 2 lower frames.
HINT: Remove the lower frames through the service hole.
17. REMOVE DOOR LOCK
a. Remove the door lock control knob.
b. Disconnect the control cable from the clamp.
c. Disconnect the 2 links from the outside handle and key cylinder.
d. w/ Power door lock:
Disconnect the connector and remove the bolt and 3 screws.
Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf)
e. w/o Power door lock:
Remove the 3 screws.
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 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
f. Remove the door lock through the service hole.
HINT: At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding and rotating parts of the door lock.
18. REMOVE DOOR LOCK LINK GUIDE AND CLAMP
a. 2-Door vehicle:
Using a screwdriver, remove the door lock link guide and 2 clamps.
b. 4-Door vehicle:
Using a screwdriver, remove the door lock link guide and clamp.
HINT: Tape the screwdriver tip before use.
19. REMOVE OUTSIDE HANDLE
a. Remove the 2 bolts and outside handle with key cylinder.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
b. Remove the bolt and key cylinder from the outside handle.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
REASSEMBLY
Reassembly is in the reverse order of disassembly.