Disassembly and Reassembly

FRONT DOOR DISASSEMBLY





1. REMOVE DOOR INSIDE HANDLE BEZEL
(a) Using a screwdriver, pry out the bezel.

HINT: Tape the screwdriver tip before use.

(b) Pull the bezel rearwards to remove it.

2. REMOVE DOOR TRIM





(a) Remove the upper bracket garnish.
(b) Remove the armrest cover.
(c) Remove a cap.
(d) Remove 2 screws.
(e) Remove 2 clips.
(f) Insert the screwdriver between the panel and the trim and remove the clips.
(g) Pull the trim upwards to remove it.
(h) Disconnect the connectors.





(i) Remove 4 screws and the side ventilator duct.
(j) Remove 9 screws and the door pocket.
(k) Remove 3 screws and the speaker grill.
(l) Remove 3 screws and the armrest base panel.
(m) Remove courtesy light.





3. REMOVE SPEAKER
(a) Remove 3 screws and the speaker.
(b) Disconnect the connector.





4. REMOVE DOOR BELT MOULDING
(a) Remove the screw from the front edge of the moulding.
(b) Pry loose the clips from the edge of the panel and remove the moulding.





5. REMOVE DOOR WEATHERSTRIP
While pulling the weatherstrip by hand, remove the 18 clips using a clip remover.

HINT: Do not pull strongly on the weatherstrip as it may tear.





6. REMOVE OUTSIDE REAR VIEW MIRROR
(a) Remove the screw and the speaker.
(b) Remove 2 screws and the mirror.
(c) Disconnect the connector.





7. REMOVE DOOR INSIDE HANDLE
(a) Remove 3 screws.
(b) Disconnect the 2 links from the handle.

8. REMOVE WINDOW OPENING PLATE

9. REMOVE SERVICE HOLE COVER
(a) Remove the cover by pulling at the edge by hand taking care not to tear the cover.
(b) Remove the steel cover.





10. DISCONNECT OPENING CONTROL LINK AND INSIDE LOCKING LINK
(a) Using a clip remover, remove the clip.
(b) Disconnect the opening control link and the inside locking link.





11. REMOVE DOOR GLASS STOPPERS
Remove 2 nuts and 2 stoppers.

12. REMOVE DOOR GLASS





(a) Remove 3 bolts.





(b) Pull the door glass out of the panel carefully.





13. REMOVE DOOR INSIDE PANEL PLATE
Remove the bolt and the plate.





14. REMOVE WINDOW REGULATOR
(a) Remove 8 nuts and the regulator.
(b) Disconnect the connector.





15. REMOVE DOOR LOCK
(a) Disconnect the 2 links from the outside handle and key cylinder.
(b) Disconnect the connector.
(c) Remove 3 screws and the door lock.





16. REMOVE OUTSIDE HANDLE AND KEY CYLINDER
(a) Remove 2 bolts and the handle.
(b) Remove the bolt and the key cylinder from the handle.

17. REMOVE SIDE PROTECTION MOULDING





18. REMOVE FRONT DOOR MIRROR BRACKET
Remove 2 bolts, the nut and the bracket.





19. REMOVE DOOR INSIDE PANEL FRAME
Remove 3 screws and the frame.





DOOR GLASS REPLACEMENT

1. REMOVE FOLLOWING PARTS:
(a) Nut
(b) Stabilizers

2. REPLACE DOOR GLASS

3. INSTALL DOOR GLASS PARTS
Install the parts by following removal sequence in reverse.

FRONT DOOR ASSEMBLY





1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE
Apply MP grease to the sliding surface and gears of~ the window regulator.

NOTICE: Do not apply MP grease to the spring of the window regulator.





2. INSTALL DOOR INSIDE PANEL FRAME
Install the frame with 3 screws.





3. INSTALL FRONT DOOR MIRROR BRACKET
Install the bracket with 2 bolts and the nut.

4. INSTALL SIDE PROTECTION MOULDING





5. INSTALL OUTSIDE HANDLE AND KEY CYLINDER
(a) Install the key cylinder to the outside handle with the bolt.
(b) Install the handle with 2 bolts.





6. INSTALL DOOR LOCK
(a) Apply adhesive to 3 screws.

Part No.08833-00070. THREE BOND 1324 or equivalent

(b) Install the door lock with 3 screws.
(c) Install the 2 links to the outside handle and key cylinder.
(d) Connect the connector.

Torque: 5.4 N.m (55 kgf.cm, 48 in.Ibf)





7. INSTALL WINDOW REGULATOR
(a) Install the regulator with 8 nuts.

Torque: 5.4 N.m (55 kgf.cm, 48 in.Ibf)

(b) Connect the connector.





8. INSTALL DOOR INSIDE PANEL PLATE
Temporarily tighten the bolt and the plate.

HINT: Tighten the bolt after door glass adjustment.

9. INSTALL DOOR GLASS





(a) Insert the glass inside the door panel.

HINT: Insert a shop rag inside the panel to prevent scratching the glass.





(b) Temporarily tighten 3 bolts.





10. INSTALL DOOR GLASS STOPPERS
Install 2 stoppers with 2 bolts.





11. CONNECT OPENING CONTROL LINK AND INSIDE LOCKING LINK.
(a) Connect the opening control link and the inside locking link with the door lock.
(b) Install the clip.

12. ADJUST DOOR GLASS





(a) Adjust lateral position of upper part of door glass. Loosen the 2 nuts, then adjust the stud bolts using a hexagon wrench.





(b) Adjust the front/rear position and the horizontal inclination of the door glass. Loosen the 3 nuts, then adjust the door glass.





(c) After adjustment is performed, check the following items:
- When the door is closed with the door glass then fully closed or else the door glass is fully closed with the door then closed, check that cross-section A- A and B-B are as specified in the illustration.
- With the door glass fully closed and the door is then closed, check that the weatherstrip is not pinched and that the door glass is not in contact with the roof drip moulding.
- When the door glass is fully closed, check that the outside edge of the door glass is in contact with the weatherstrip at the front pillar and roof side and that the edge of the glass cannot be seen.
- Check that the door glass is not loose when it is half open.
- When the door glass is rising up, check that the door glass and roof side weatherstrip are parallel and that the door glass contacts the 2 upper plates.
- Check that the door glass moves up and down smoothly over all areas.





13. ADJUST FRONT DOOR MIRROR BRACKET
(a) Remove the bolt.
(b) Rotate the nut and adjust the lateral position of the mirror bracket.
(c) Check that the bracket is aligned with the angle of the door glass.





14. INSTALL SERVICE HOLE COVER
(a) Install the steel plate.
(b) Seal the service hole cover with adhesive.

HINT: Bring out the links through the service hole cover.





15. INSTALL DOOR INSIDE HANDLE
(a) Install the handle with 3 screws.
(b) Connect 2 links.





16. INSTALL DOOR BELT MOULDING
(a) Install the claw of the clips into the upper panel slit and push the moulding onto the panel.
(b) Install the screw to the moulding.





17. INSTALL DOOR WEATHERSTRIP
Push down on the 16 clips and install the weatherstrip.





18. INSTALL OUTSIDE REAR VIEW MIRROR
(a) Connect the connector.
(b) Install the mirror with 2 screws.
(c) Install the speaker with the screw.





19. INSTALL SPEAKER
(a) Connect the connector.
(b) Install the speaker with 3 screws.

20. INSTALL DOOR TRIM
(a) Install courtesy light.





(b) Install the armrest base panel with 3 screws.
(c) Install the speaker grill with 3 screws.
(d) Install the door pocket with 9 screws.
(e) Install the side ventilator duct with 4 screws.





(f) Insert the upper edge of the trim from above, tap the trim by hand fix it in place with the clips. then connect the connectors.
(g) Install 2 clips.
(h) Install 2 screws and the cap.
(i) Install the armrest cover.
(j) Install the upper bracket garnish.





21. INSTALL DOOR INSIDE HANDLE BEZEL
Install the door inside handle bezel.