Front door
Components Removal / installation
DOOR / TRUNK
FRONT DOOR
EXPLODED VIEW
DISASSEMBLY
NOTE:
The following procedure is for LH side. Unless otherwise specified, perform the same procedures for the LH and RH side.
1. Disconnection of the battery ground terminal (Refer to 
)
)
2. Removal of the door armrest cover LH
3. Removal of the courtesy light ASSY (if there is a courtesy light) (Refer to )
)
4. Removal of the front door trim board SUB-ASSY LH
(1) Using a flat tip screwdriver that is wrapped in protective tape, open the cap.
Captions in illustration
| *1 |
Protective tape |
(2) Remove the clip.
(3) Remove the 3 screws.
(4) While pulling the front door trim board SUB-ASSY towards, release the 10 clips in the order shown in the figure.
(5) Disconnect each connector.
(6) Disconnect the front door lock remote control cable and the front door inside locking cable from the front door trim board SUB-ASSY LH.
5. Removal of the front door inside handle SUB-ASSY LH
(1) Remove the 2 screws.
(2) Release the 2 guides, and remove the front door inside handle SUB-ASSY LH and the plate.
6. Removal of the power window regulator master switch ASSY W/ front armrest base panel UPR LH (driver side door)
(1) Remove the 4 screws.
(2) Release the tab, and remove the power window regulator master switch ASSY W/ front door armrest base panel.
7. Removal of the power window regulator master switch ASSY (driver side door) (Refer to )
)
8. Removal of the power window regulator switch ASSY W/ front armrest base panel UPR RH (passenger side door)
(1) Remove the 4 screws.
(2) Release the tab, and remove the power window regulator switch ASSY W/ front door armrest base panel.
9. Removal of the power window regulator switch ASSY (passenger side door) (Refer to )
)10. Removal of the outer mirror switch ASSY (Refer to )
)
11. Removal of the door assist grip ASSY LH
(1) Remove the 2 screws.
(2) Release the guide, and remove the door assist grip ASSY LH.
12. Removal of the front door trim pad LWR LH (2-speaker type)
(1) Remove the 5 screws, and remove the front door trim pad LWR LH.
13. Removal of the front door trim pad LWR LH (other than 2-speaker type)
(1) Remove the 5 screws, and remove the front door trim pad LWR LH.
14. Removal of the front door speaker LH (other than 2-speaker type)
(1) Remove the 2 screws, and remove the front door speaker LH.
(2) Remove the front door speaker grill LH from the front door speaker LH.
15. Removal of the front door glass weather strip INN LH
(1) Set the 4 mm {0.1575 in} drill bit in the air drill.
(2) Wrap tape around the 4 mm {0.1575 in} drill bit about 5 mm {0.1969 in} behind the tip.
NOTE:
Wrapping the tape prevents grinding too deep.
(3) Lightly press the air drill against the rivet, grind the flange portion of the rivet, and remove the 6 rivets.
CAUTION:
·If you press the air drill to hard, the rivet will turn together, and will not be cut.
·If you pry with the air drill while grinding, you may grind the hole where the rivet is installed or may damage the drill bit.
·Be careful, because the cut rivet will be hot.
·If you pry with the air drill while grinding, you may grind the hole where the rivet is installed or may damage the drill bit.
·Be careful, because the cut rivet will be hot.
Captions in illustration
| *1 |
Air drill |
- |
- |
| a |
5 mm {0.1969 in} |
- |
- |
(4) Release the 9 tabs, and remove the front door glass weather strip INN RH.
16. Removal of the speaker ASSY FR NO. 1 (if there is a speaker) (Refer to )
)
17. Removal of the front door service hole cover LH
(1) Disconnect the connectors for the front door lock ASSY and the outer rear-view mirror ASSY.
(2) Remove the front door service hole cover LH.
CAUTION:
Remove any butyl tape left on the door panel.
18. Removal of the outer rear-view mirror LH (Refer to )
)19. Removal of the front door glass weather strip ASSY OUT RH (Refer to )
)
20. Removal of the front door glass SUB-ASSY LH
(1) Reconnect the battery ground terminal.
(2) Connect the power window regulator master switch ASSY connector and move the front door glass SUB-ASSY LH until you can see the front door glass SUB-ASSY LH mounting bolt.
(3) Disconnect the battery ground terminal.
(4) Disconnect the power window regulator master switch ASSY connector.
(5) Remove the 3 nuts, disconnect the front door frame SUB-ASSY RR LWR LH, and slide the front door frame SUB-ASSY RR LWR LH beyond the mounting section.
(6) Remove the 2 nuts and disconnect the front glass SUB-ASSY LH.
(7) Loosen the front stabilizer mounting bolt.
CAUTION:
Be sure to hold the front glass SUB-ASSY LH and the front door frame SUB-ASSY RR LWR LH securely so that they don't fall.
Captions in illustration
| *1 |
Front stabilizer mounting bolt |
(8) Remove the front door rear cover LH, and turn over the front door weather strip rear end so that the front glass SUB-ASSY LH can be removed.
(9) While lifting the front glass SUB-ASSY LH up, let the front door frame SUB-ASSY RR LWR LH slide down, and pull the front glass SUB-ASSY LH out from the front door frame SUB-ASSY RR LWR LH.
CAUTION:
·Be sure to hold the front glass SUB-ASSY LH and the front door frame SUB-ASSY RR LWR LH securely so that they don't fall.
·Do not damage the front door glass.
·Do not damage the front door glass.
(10) From the position shown in the figure, remove the front glass SUB-ASSY LH.
CAUTION:
Do not damage the front door weather strip.
NOTE:
The front glass SUB-ASSY LH cannot be removed from any position other than the one in the figure.
21. Removal of the front door frame SUB-ASSY RR LWR LH.
(1) Remove the front door frame SUB-ASSY RR LWR LH from the front door frame.
22. Removal of the door glass stabilizer INN
(1) Remove the bolt and remove the door glass stabilizer INN.
23. Removal of the front door sash
(1) Remove the 3 nuts.
(2) In the order shown in the figure, turn the front door sash, and pull it out.
CAUTION:
·The mounting bolt of the front door sash will interfere, so be sure to perform this task in the order in the figure.
·To avoid damaging the glass, hold it securely.
·To avoid damaging the glass, hold it securely.
24. Removal of the front door sash stopper
(1) Remove the nut and remove the front door sash stopper.
25. Removal of the front door window regulator W/ motor ASSY
(1) Disconnect the connector.
(2) Loosen the tack bolt.
CAUTION:
If you remove the tack bolt, and the other 3 bolts and 2 nuts are removed, the front door window regulator W/ motor ASSY may fall and be disfigured. Do not remove it.
(3) Remove the 3 bolts and the 2 nuts.
26. Removal of the power window regulator motor ASSY LH (Refer to )
)27. Removal of the front door weather strip LH
(1) For the remaining front door weather strip LH, using a clip remover, release the 15 clips, and remove the front door weather strip LH.
28. Removal of the front door outside handle cover W/ lock cylinder ASSY (driver side door)
(1) Using a Torx socket wrench, remove the Torx screw, and remove the front door outside handle cover W/ lock cylinder ASSY.
29. Removal of the front door outside handle cover FD (driver side door)
(1) Using a flat tip screwdriver, release the tab and the 2 guides, and remove the front door outside handle cover FD from the front door lock cylinder ASSY.
30. Removal of the front door outside handle cover FP (passenger side door)
(1) Using a Torx socket wrench, remove the Torx screw, and remove the front door outside handle cover FP.
31. Removal of the front door lock ASSY LH (Refer to )
)
32. Removal of the front door outside handle ASSY LH
(1) Pull the front door outside handle ASSY LH towards the back of the vehicle, and release the front door outside handle frame SUB-ASSY LH.
(2) Pull the front door outside handle ASSY LH towards you, and remove it from the front door outside handle frame LH.
33. Removal of the front door outside handle ASSY LH (if there is smart entry)
(1) Use the clip remover to release the clamp.
(2) Using a thin flat tip screwdriver that is wrapped in protective tape, release the 3 tabs and lift the connector cover.
Captions in illustration
| *1 |
Protective tape |
(3) Disconnect the connector.
(4) Pull the front door outside handle ASSY LH towards the back of the vehicle, and release the front door outside handle frame SUB-ASSY LH.
(5) Pull the front door outside handle ASSY LH towards you, and remove it from the front door outside handle frame SUB-ASSY LH.
34. Removal of the front door outside handle pad FR
(1) Release the 3 tabs and remove the front door outside handle pad FR.
35. Removal of the front door outside handle pad RR
(1) Release the 2 tabs and remove the front door outside handle pad RR.
36. Removal of the front door lock open rod LH
(1) In the order shown in the figure, release the front door outside handle snap, and remove the front door lock open rod LH.
37. Removal of the front door outside handle frame SUB-ASSY LH
38. Removal of the front door check ASSY
(1) Remove the bolt and the 2 nuts and remove the front door check ASSY.
39. Removal of the front door panel cushion
(1) Release the tabs and remove the 2 front door panel cushions.
40. Removal of the side air bag sensor ASSY LH (Refer to )
)
41. Removal of the front door hole cover
(1) Release the 4 tabs and remove the front door hole cover.
ASSEMBLY
NOTE:
The following procedure is for LH side. Unless otherwise specified, perform the same procedures for the LH and RH side.
1. Applying of body grease
(1) Apply body grease to the sliding parts of the front door window regulator, the front door check ASSY LH, the front door outside handle frame SUB-ASSY LH, and the front door lock ASSY LH.
2. Installation of the front door hole cover
(1) Fit in the 4 tabs and install the front door hole cover.
3. Installation of the side air bag sensor ASSY LH (Refer to )
)
4. Installation of the front door panel cushions
(1) Fit in the 2 tabs and install the 2 front door panel cushions.
5. Installation of the front door check ASSY
(1) Using 2 nuts, install the front door check ASSY.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(2) Install the bolt.
Standard value:
Standard value:
Tightening torque=33N·m
{
336kgf·cm}
{24.3ft·lbf}
6. Installation of the front door outside handle frame SUB-ASSY LH
(1) Pull towards the back of the vehicle, fit in the tab, and temporarily install the front door outside handle frame SUB-ASSY LH on the front door panel.
7. Installation of the front door lock open rod LH
(1) In the order shown in the figure, fit in the front door outside handle snap, and attach the front door lock open rod LH to the front door outside handle frame LH.
8. Installation of the front door outside handle pad FR
(1) Fit in the 3 tabs and install the front door outside handle pad FR.
9. Installation of the front door outside handle pad RR
(1) Fit in the 2 tabs and install the front door outside handle pad RR.
10. Installation of the front door outside handle ASSY LH (if there is smart entry)
(1) Insert the front end of the front door outside handle ASSY LH into the front door outside handle frame SUB-ASSY LH.
(2) Insert the rear end of the front door outside handle ASSY LH into the front door outside handle frame SUB-ASSY LH, and install it by sliding it towards the front of the vehicle.
(3) Connect the connector.
(4) Fit in the 3 claws.
(5) Fit in the clamp.
11. Installation of the front door outside handle ASSY LH (if there is no smart entry)
(1) Insert the front end of the front door outside handle ASSY LH into the front door outside handle frame SUB-ASSY LH.
12. Installation of the front door lock ASSY LH (Refer to )
)
13. Installation of the front door outside handle cover FD (driver side door)
(1) Fit in the tab and the 2 guides, and install the front door outside handle cover FD on the front door lock cylinder ASSY.
14. Installation of the front door outside handle cover W/ lock cylinder ASSY (driver side door)
(1) Assemble the front door outside handle cover W/ lock cylinder ASSY.
NOTE:
Check that the front door lock cylinder rod is inserted into the front door lock ASSY LH.
(2) Using a Torx socket wrench and a Torx screw, install the front door outside handle cover W/ lock cylinder ASSY.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
15. Installation of the front door outside handle cover FP (passenger side door)
(1) Using a Torx socket wrench and a Torx screw, install the front door outside handle cover FP.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
16. Installation of the front door weather strip LH.
(1) Fit in the 15 clips.
(2) Install the 3 rear sections after installing the front door glass weather strip ASSY OUT LH.
17. Installation of the power window regulator motor ASSY LH (Refer to )
)
18. Installation of the front door window regulator W/ motor ASSY
(1) With the tack bolt, temporarily install the front door window regulator W/ motor ASSY on the front door panel.
(2) With 3 bolts and 2 nuts, install the front door window regulator W/ motor ASSY.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(3) Completely tighten the tack bolt.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
19. Installation of the front door sash stopper
(1) Install the front door sash stopper with a bolt.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
20. Installation of the front door sash
(1) As in the figure, insert the front door sash into the front door frame at a right angle.
CAUTION:
·The mounting bolt of the front door sash will interfere, so be sure to perform this task in the order in the figure.
·To avoid damaging the front door sash, hold it securely.
·To avoid damaging the front door sash, hold it securely.
(2) Turn the front door sash 90°.
(3) Using 3 nuts, install the front door sash.
Standard value:
Standard value:
Standard value:
Nut (A)
Tightening torque=14N·m { 143kgf·cm} {10.3ft·lbf}
Tightening torque=14N·m { 143kgf·cm} {10.3ft·lbf}
Standard value:
Nut (B)
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf}
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf}
21. Installation of the front door frame SUB-ASSY RR LWR RH
(1) Using 3 nuts, install the front door sash RR.
Standard value:
Standard value:
Tightening torque=14N·m
{
143kgf·cm}
{10.3ft·lbf}
22. Installation of the front door glass SUB-ASSY LH
(1) Reconnect the battery ground terminal.
(2) Connect the power window regulator master switch ASSY connector and move the front door window regulator until you can see where the front door glass SUB-ASSY LH is installed.
(3) Disconnect the battery ground terminal.
(4) Disconnect the power window regulator master switch ASSY connector.
(5) From the position shown in the figure, insert the front door glass SUB-ASSY LH into the front door frame.
CAUTION:
Do not damage the front door weather strip LH.
NOTE:
Because the front door glass SUB-ASSY LH cannot be installed in a position other than the one in the figure, perform this task while sliding the front door frame SUB-ASSY RR LWR LH.
(6) Set the grommet part of the front door glass SUB-ASSY LH into the rail of the front door frame SUB-ASSY RR LWR LH.
CAUTION:
·To avoid dropping the front door glass SUB-ASSY LH and the front door frame SUB-ASSY RR LWR LH, hold them securely.
·Do not damage the front door glass.
·Do not damage the front door glass.
(7) Using 2 nuts, install the front door glass SUB-ASSY LH.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
23. Installation of the door glass stabilizer INN
(1) Install the door glass stabilizer INN with a bolt.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
24. Adjustment of the front door glass SUB-ASSY LH
(1) Inspect the front door glass installation. (Refer to )
)(2) Adjust the placement of the front door glass. (Refer to )
)25. Installation of the front door glass weather strip ASSY OUT LH (Refer to )
)26. Install the rear end of the front door weather strip LH, and install the front door rear cover LH.
27. Installation of the outer rear-view mirror LH (Refer to )
)28. Installation of the front door service hole cover LH
(1) Apply new butyl tape to the door panel.
CAUTION:
·The butyl tape must overlay for 20 cm {7.874 in} or more.
·The butyl tape must not block the water draining holes in the front door panel.
·The butyl tape must not block the water draining holes in the front door panel.
(2) Put the front door lock remote control cable LH, the rear door inside locking cable LH and every connector through the new front door service hole cover LH.
(3) Align the new front door service hole cover LH with the front door panel standard position, and apply.
CAUTION:
To avoid wrinkles and bubbles, push with enough force when applying the front door service hole cover LH.
29. Installation of the speaker ASSY FR NO.1 (if there is a speaker) (Refer to )
)
30. Installation of the front door glass weather strip INN LH.
(1) As in the figure, fit in the 9 tabs and install the new front door glass weather strip INN LH on the front door trim board SUB-ASSY LH.
(2) Fit in the tab.
(3)
Equip nosepiece No.1 to the air riveter (a product that supports φ3.2 mm {0.13 in}), and insert the mandrel of the new rivet into the nosepiece.
(4) Once the rivets have been vertically pushed into the installation holes, use the air riveter to install the 6 rivets.
(5) If you can’t cut the shaft, pull again to cut off the shaft, removing the head as well.
Preparation tool & preparation items
: Air riveter (product that supports φ 3.2 mm {0.13 in})
: Rivet
(6) After installing the rivet, cut non-woven tape into a 15 mm×15 mm {0.59 in × 0.59 in} square and apply to the crimped section.
CAUTION:
The crimped section of the rivet should be 3 mm {0.12 in} high. It may interfere with the door panel. If the crimping is insufficient, push it down with pliers.
Preparation items
: Non-woven tape: 94029FG000
Captions in illustration
| *1 |
Window glass |
| *2 |
Door trim |
| *3 |
Non-woven tape |
| *4 |
Rivet |
| *5 |
Weather strip INN |
(7) After installing the weather strip INN, perform the following inspections.
·There is no gap between the weather strip INN LH and the front door trim board SUB-ASSY LH.
·There is no looseness when you lightly pull on the weather strip INN LH.
·There is no looseness when you lightly pull on the weather strip INN LH.
31. Installation of the front door trim pad LWR LH (2-speaker type)
(1) Using 5 screws, install the front door trim pad LWR LH.
32. Installation of the front door speaker LH (other than 2-speaker type)
(1) Install the front door speaker grill LH on the front door speaker LH.
(2) Using 2 screws, install the front door speaker LH.
33. Installation of the front door trim pad LWR LH (other than 2-speaker type)
(1) Using 5 screws, install the front door trim pad LWR LH.
34. Installation of the door assist grip ASSY LH
(1) Fit in the guide, and with 2 screws, install the door assist grip ASSY LH.
35. Installation of the outer mirror switch ASSY (Refer to )
)36. Installation of the power window regulator master switch ASSY (driver side door) (Refer to )
)
37. Installation of the power window regulator master switch ASSY W/ front armrest base panel UPR LH (driver side door)
(1) Fit in the tab, and using 4 screws, install the power window regulator master switch ASSY W/ front armrest base panel UPR LH on the front door trim board SUB-ASSY LH.
38. Installation of power window regulator switch ASSY (passenger side door) (Refer to )
)
39. Installation of the power window regulator switch ASSY W/ front armrest base panel UPR RH (passenger side door)
(1) Fit in the tab, and using 4 screws, install the power window regulator switch ASSY W/ front armrest base panel UPR RH on the front door trim board SUB-ASSY RH.
40. Installation of the front door inside handle SUB-ASSY LH
(1) Fit in the 2 guides.
(2) Using 2 screws, install the front door inside handle SUB-ASSY LH with the plate on the front door trim board SUB-ASSY LH.
41. Installation of the front door trim board SUB-ASSY LH
(1) Connect the front door lock remote control cable LH and the front door inside locking cable LH to the door remote ASSY LH.
(2) Connect each connector.
(3) Insert the upper side of the front door trim board SUB-ASSY LH first.
(4) Fit in the 10 clips and install the front door trim board SUB-ASSY LH on the front door panel.
CAUTION:
When installing the front door panel, do not hit the shaded area.
(5) Install the 3 screws and a clip.
(6) Fit in the tab and install the cap.
42. Installation of the courtesy light ASSY (Refer to )
)
43. Installation of the door armrest cover LH
(1) Fit in the 7 tabs and the guide, and install the door armrest cover LH.
44. Connection of the battery ground terminal
Standard value:
Standard value:
Tightening torque=6.0N·m
{
61kgf·cm}
{4.4ft·lbf}
45. Power window registration settings (Refer to )
)46. Function inspection of the power windows (Refer to )
)ADJUSTMENT
NOTE:
The following procedure is for LH side. Perform the same procedures for the RH and LH side.
1. Inspection of the front door LH
(1) Inspect if each placement dimension is within the reference values.
Captions in illustration
| *1 |
Front glass |
*2 |
Front door |
Reference values
| *a |
-1.0 to 2.0 mm {-0.039 to 0.079 in} |
*b |
5.5 to 8.5 mm {0.217 to 0.335 in} |
| *c |
3.5 to 6.5 mm {0.138 to 0.256 in} |
*d |
5.2 to 8.2 mm {0.205 to 0.323 in} |
| *e |
13.5 to 16.5 mm {0.5315 to 0.6496 in} |
*f |
2.5 to 5.5 mm {0.0984 to 0.2165 in} |
| *g |
0.0 to 1.5 mm {0.0 to 0.0591 in} |
*h |
4.8 to 7.8 mm {0.1890 to 0.3071 in} |
| *i |
3.1 to 5.6 mm {0.122 to 0.220 in} |
*j |
-1.0 to 1.5 mm {-0.0394 to 0.0591 in} |
2. Adjustment of the front door glass
(1) Insert the SST in the front door glass and measure the placement dimensions.
SST
61299CA000
Captions in illustration
| *1 |
SST |
Reference values
| *a |
3.5 to 6.5 mm {0.138 to 0.256 in} |
| *b |
5.2 to 8.2 mm {0.205 to 0.323 in} |
(2) Adjust the front door glass so that the placement dimensions are within the reference values.
(3) Loosen the nut of the front door sash stopper and the bolt of the front door frame SUB-ASSY RR LWR RH stopper section, and adjust the vertical direction of the front door glass.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(4) Loosen the 2 nuts of the front door frame SUB-ASSY RR LWR RH, and adjust the forward and backward direction of the front door glass.
Standard value:
Standard value:
Tightening torque=14N·m
{
143kgf·cm}
{10.3ft·lbf}
(5) Loosen the bolt of the door glass stabilizer INN, and adjust the side to side direction of the front door glass.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(6) Loosen the nut of the front door frame SUB-ASSY RR LWR RH, turn the bolt with a flat tip screwdriver, and adjust the side to side direction of the front door glass.
Standard value:
Standard value:
Tightening torque=14N·m
{
143kgf·cm}
{10.3ft·lbf}
(7) Insert the SST in the side fix window and measure the placement dimensions.
SST
61299CA010
Captions in illustration
| *1 |
SST |
Reference values
| *a |
2.5 to 5.5 mm {0.0984 to 0.2165 in} |
| *b |
5.2 to 8.2 mm {0.2047 to 0.3228 in} |
(8) Loosen the nut of the front door sash and adjust the vertical direction of the front door sash so that the placement dimensions are within the reference values.
Standard value:
Standard value:
Tightening torque=14N·m
{
143kgf·cm}
{10.3ft·lbf} (lower side)
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf} (upper side)
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf} (upper side)
3. Adjustment of the front door LH
(1) Loosen the bolts on the body side, and adjust the door's front and rear, and vertical directions.
Standard value:
Standard value:
Tightening torque=30N·m
{
306kgf·cm}
{22.1ft·lbf}
(2) Loosen the striker installation screws until the striker can move. Using a brass bar, hit the striker lightly and adjust the side to side and vertical directions of the rear end of the door and the front door lock striker plate ASSY.
Standard value:
Standard value:
Tightening torque=18N·m
{
184kgf·cm}
{13.3ft·lbf}