Disassembly

DOOR / HATCH: FRONT DOOR: DISASSEMBLY

HINT
* Use the same procedure for both the RH and LH sides.
* The procedure described below is for the LH side.

1. PRECAUTION

NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER Removal

3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG

(a) Using a moulding remover, disengage the 3 claws and remove the front door inside handle bezel plug as shown in the illustration.

5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH

(a) Disengage the 3 clips and remove the front door lower frame bracket garnish.

6. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)

(a) Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

(b) Disconnect each connector and remove the power window regulator master switch assembly with front door armrest base panel.

7. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Front Passenger Side)

(a) Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

(b) Disconnect each connector and remove the power window regulator switch assembly with front door armrest base panel.

8. REMOVE FRONT ARMREST ASSEMBLY

(a) Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the front armrest assembly.

9. REMOVE COURTESY LIGHT ASSEMBLY Removal

10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Put protective tape around the front door panel.

Text in Illustration

(b) Remove the 3 screws.

(c) Using a clip remover, disengage the 10 clips.

(d) Pull out the front door trim board sub-assembly in the direction indicated by the arrow as shown in the illustration.

Text in Illustration

(e) Disengage the reference boss from the front door panel.

(f) Raise the front door trim board sub-assembly to remove the front door trim board sub-assembly together with the front door inner glass weatherstrip.

(g) Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.

11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Disengage the 2 claws and guides, and remove the front door inside handle sub-assembly.

12. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Using a screwdriver, disengage the 4 claws and remove the front door inner glass weatherstrip from the front door trim board sub-assembly as shown in the illustration.

Text in Illustration

13. REMOVE DOOR SIDE AIRBAG SENSOR Removal

14. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY Removal

15. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY Removal

16. REMOVE FRONT DOOR SERVICE HOLE COVER

(a) Remove the bolt.

(b) Disconnect each connector.

(c) Disengage the 5 clamps.

(d) Remove the front door service hole cover.

HINT
Remove any remaining butyl tape from the door.

17. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY

(a) Remove the grommet.

(b) Connect the cable to the negative (-) auxiliary battery terminal.

(c) Connect the power window regulator master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

(d) Disconnect the cable from the negative (-) auxiliary battery terminal.

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) auxiliary battery terminal to disable the SRS system.

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

(e) Disconnect the power window regulator master switch assembly.

(f) Remove the 2 bolts.

NOTICE:
After the bolts are removed, do not allow the door glass to fall.

(g) Remove the front door glass sub-assembly as indicated by the arrows, in the order shown in the illustration.

NOTICE:
Do not damage the door glass.

18. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY

(a) Loosen the temporary bolt.

Text in Illustration

NOTICE:
Do not remove the temporary bolt. If the temporary bolt is removed, the front door window regulator may fall and cause damage.

(b) Remove the 5 bolts.

(c) Remove the front door window regulator assembly.

(d) Remove the temporary bolt from the front door window regulator assembly.

19. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY

(a) Using a T25 "TORX" socket wrench, remove the 3 screws and front power window regulator motor assembly.

20. REMOVE NO. 2 FRONT DOOR STIFFENER CUSHION

(a) Remove the 2 bolts.

Text in Illustration

(b) Disengage the 2 guides and remove the No. 2 front door stiffener cushion.

21. REMOVE FRONT DOOR GLASS RUN

(a) Remove the front door glass run.

22. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

(a) Remove the 2 bolts.

(b) Disengage the guide and remove the front door front lower frame sub-assembly as shown in the illustration.

23. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Remove the 2 bolts.

(b) Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration.

24. REMOVE FRONT DOOR OUTSIDE HANDLE COVER WITH LOCK CYLINDER ASSEMBLY (for Driver Side)

(a) Remove the hole plug.

(b) Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover with lock cylinder assembly.

HINT
The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

25. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)

(a) Using a screwdriver, disengage the claw and 2 guides, and remove the front door outside handle cover as shown in the illustration.

26. REMOVE FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)

(a) Remove the hole plug.

(b) Using a T30 "TORX" socket wrench, loosen the screw and remove the front door outside handle cover.

HINT
The screw cannot be removed because it is integrated into the front door outside handle frame sub-assembly.

27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY

(a) Disengage the 2 claws.

(b) Using a screwdriver, disconnect the connector.

28. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Disengage the 3 claws and remove the front door front outside handle pad.

29. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Disengage the 2 claws and remove the front door rear outside handle pad.

30. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY

(a) Using a T30 "TORX" socket wrench, remove the 3 screws.

Text in Illustration

(b) Slide the front door lock with motor assembly downward, and remove the front door lock with motor assembly and cables as a unit.

(c) When reusing the front door lock with motor assembly:

(1) Remove the door lock wiring harness seal from the front door lock with motor assembly.

31. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

(a) Remove the front door lock remote control cable assembly.

32. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Using a screwdriver, disengage the 3 claws.

(b) Remove the front door inside locking cable assembly.

33. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Disconnect the connector.

(b) Disengage the 3 clamps.

(c) Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

Text in Illustration

(d) Slide the front door outside handle frame sub-assembly to disengage the claw of the front door outside handle frame sub-assembly, and then remove it.

34. REMOVE FRONT DOOR WIRE

(a) Disengage the 3 clamps and remove the front door wire.

35. REMOVE FRONT DOOR LOCK OPEN ROD

(a) Remove the front door lock open rod as indicated by the arrows, in the order shown in the illustration.

36. REMOVE FRONT DOOR CHECK ASSEMBLY

(a) Remove the 3 bolts and front door check assembly.

37. REMOVE FRONT DOOR WEATHERSTRIP

(a) Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.

38. REMOVE DOOR FRAME GARNISH

(a) Disengage the clip and remove the door frame garnish.

HINT
This garnish needs to be replaced with a new one because the clip will break when removing it.

39. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP

(a) Using a clip remover, disengage the 8 clips and remove the front door No. 2 weatherstrip.

40. REMOVE FRONT DOOR PANEL CUSHION

(a) Disengage the 2 claws and remove the 2 front door panel cushions.

41. REMOVE DOOR DUST PROOF SEAL

(a) Remove the door dust proof seal.

42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY

43. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING

44. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING

45. REMOVE FRONT DOOR STRIPE

46. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE