Front Door: Service and Repair

FRONT DOOR

Front Door:

Front Door:

DISASSEMBLY

HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.
- A bolt without a torque specification is shown in the standard bolt chart.

1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH






a. Using a screwdriver, disengage the clip and claw, and remove the front door lower frame bracket garnish LH.

HINT: Tape the screwdriver tip before use.

2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH






a. Using a screwdriver, disengage the 3 claws and remove the front door inside handle bezel plug LH.

3. REMOVE FRONT ARMREST BASE PANEL UPPER LH






a. Using a screwdriver, disengage the 2 clips and 2 claws, and remove the armrest base panel upper LH with the power window regulator master switch.
b. Disconnect the switch connector.

4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY LH






a. Remove the 3 screws.






b. Using a clip remover, disengage the 9 clips (A) and 4 clips (B) on top.
c. Remove the trim inboard.

HINT: If a clip cannot be reached with the clip remover, pull on the lower trim to remove it.






d. Disconnect the 2 cables.
e. Disconnect the wire harness connector from the courtesy light.

5. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Remove the outer rear view mirror assembly LH.

6. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY
a. Disconnect the connectors.






b. Remove the 2 screws and the outer mirror control ECU assembly.

7. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY
a. Remove the front No. 1 speaker assembly.

8. REMOVE FRONT DOOR SERVICE HOLE COVER LH






a. Remove the front door service hole cover LH.

NOTICE: Remove the remaining tape on the door side.

9. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY LH
10. REMOVE FRONT DOOR WINDOW FRAME MOULDING REAR LH
11. REMOVE FRONT DOOR MOULDING SUB-ASSEMBLY OUTSIDE LH
12. REMOVE FRONT DOOR GLASS WEATHERSTRIP INNER LH
13. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY






a. Remove the 2 bolts and the front door glass subassembly LH.

NOTICE: Be careful not to damage the glass.

14. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH






a. Remove the 6 bolts and the front door window regulator sub-assembly LH.

15. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT






a. Using a torx wrench (T25), remove the 3 torx screws and the power window regulator motor assembly LH front.

16. REMOVE FRONT DOOR GLASS RUN LH






a. Remove the front door glass run LH.

17. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY FRONT LOWER LH






a. Remove the 2 bolts and the front door frame subassembly front lower LH.

HINT: Remove the frame through the speaker hole.

18. REMOVE FRONT DOOR FRAME SUB-ASSEMBLY REAR LOWER LH






a. Remove the bolt and the front door frame subassembly rear lower LH.

19. REMOVE FRONT DOOR LOCK ASSEMBLY LH
a. Disconnect the door lock connector.






b. Using a torx socket wrench (T30), remove the 3 torx screws and the front door lock assembly LH.

HINT: Remove the door lock through the service hole.

NOTICE: Be careful when removing the bolts as the door lock may fall and be damaged.

c. Remove the front door lock wire harness packing.

20. REMOVE FRONT DOOR OUTSIDE HANDLE COVER RH
a. Remove the hole plug.






b. Using a torx socket wrench (T30), loosen the torx screw and remove the front door outside handle cover LH with the door lock key cylinder installed.

21. REMOVE FRONT DOOR HANDLE ASSEMBLY OUTSIDE LH






a. Remove the handle by sliding and pulling it in the direction indicated by the arrow in the illustration.
b. Remove the outside handle pad front and rear.

NOTICE: If the bellcrank lever is not pulled and held when removing the handle, the release plate will interfere with the handle and be damaged.

22. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (w/o Smart Key System)






a. Using a torx socket wrench (T30), loosen the torx screw and remove the front door outside handle frame sub-assembly LH.

23. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (w/ Smart Key System)






a. Disconnect the connector.






b. Disconnect the clamp.
c. Using a torx socket wrench, loosen the torx screw and remove the front door outside handle frame sub-assembly LH.

24. REMOVE FRONT DOOR OUTSIDE HANDLE PAD FRONT
25. REMOVE FRONT DOOR OUTSIDE HANDLE PAD REAR
26. REMOVE FRONT DOOR CHECK ASSEMBLY LH






a. Remove the bolt, 2 nuts and the front door check assembly LH.

HINT: Remove the door check through the service hole.

NOTICE: Be careful when removing the bolts as door check may fall and be damaged.

27. REMOVE FRONT DOOR WEATHERSTRIP LH

REASSEMBLY

1. INSTALL FRONT DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding areas of the door check.






b. Install the door check to the door panel with the 2 nuts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

c. Apply adhesive to the threads of the bolt.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

d. Install the door check to the body panel with the bolt.

Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)

2. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (w/o Smart Key System)
a. Using a torx wrench (T25), install the front door outside handle frame sub-assembly LH with the torx screw.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)

3. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (w/ Smart Key System)
a. Using a torx wrench (T25), install the front door outside handle frame sub-assembly LH with the torx screw.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)

4. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH






a. Using a torx socket wrench (T30), install the cover (with the door lock key cylinder installed) with the torx screw.

Torque: 4.0 N.m (41 kgf.cm, 37 in.lbf)

b. Install the hole plug.

5. INSTALL FRONT DOOR W/MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the door lock.
b. Install a new door lock wire harness packing.

NOTICE:
- When reinstalling a door lock, always use new packing.
- Do not allow grease or dirt to contaminate the gap between the door panel and packing.
- Water will damage the door lock.
- Old packing or damaged packing cannot effectively protect the door lock against water.






c. Insert the control rod into the door lock, and then set it to the door panel.

NOTICE: Make sure that the rod is securely engaged with the lock.

d. Apply adhesive to the threads of the 3 torx screws.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent






e. Using a torx socket wrench (T30), install the door lock with the 3 torx screws.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

f. Connect the door lock connector.

6. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH FRONT






a. Using a torx wrench (T25), install the power window regulator motor assembly LH front with the 3 torx screws.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

7. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY LH






a. Install the front door window regulator sub-assembly LH with the 6 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

8. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY LH






a. Install the front door glass sub-assembly LH with the 2 bolts.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

9. INSTALL FRONT DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door.






b. Install the front door service hole cover LH, as shown in the illustration.

HINT:
- There should be no wrinkles or folds on the service hole cover after attaching.
- Check that the service hole cover is securely attached.

10. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY LH
a. Install the outer rear view mirror assembly LH.

11. INITIALIZE POWER WINDOW SYSTEM CIRCUIT
a. Initialize the power window system circuit. Programming and Relearning