Reassembly

DOOR / HATCH: FRONT DOOR: REASSEMBLY

REASSEMBLY

1. REPAIR INSTRUCTION (w/ Black Out Tape)
2. INSTALL NO. 1 BLACK OUT TAPE (w/ Black Out Tape)
3. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY
4. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION

(a) Engage the 2 guides and 2 clips, and install a new front door No. 2 stiffener cushion with double-sided tape.
5. INSTALL DOOR FRAME GARNISH

(a) Engage the claw and install a new door frame garnish.
6. INSTALL FRONT DOOR WEATHERSTRIP

(a) Engage the 15 clips and install the front door weatherstrip.
7. INSTALL FRONT DOOR CHECK ASSEMBLY

(a) Install the front door check assembly with the 3 bolts.
Bolt (1) - Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
Bolt (2) - Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
8. INSTALL FRONT DOOR LOCK OPEN ROD

(a) Install the front door lock open rod as shown in the illustration.
9. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
(a) Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.

(b) Engage the claw and grommet.
(c) Using a "TORX" socket wrench (T30), install the front door outside handle frame sub-assembly with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
10. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Power Door Lock)

(a) Install the front door inside locking cable assembly.
11. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Power Door Lock)

(a) Install the front door inside locking cable assembly.

(b) Engage the 3 claws.
12. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Power Door Lock)

(a) Install the front door lock remote control cable assembly.
13. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Power Door Lock)

(a) Install the front door lock remote control cable assembly.
14. INSTALL FRONT DOOR LOCK ASSEMBLY (w/o Power Door Lock)
(a) Apply MP grease to the sliding parts of the front door lock assembly.

(b) Insert the front door lock open rod to the front door lock assembly.
(c) Make sure that the front door lock open rod is securely connected to the front door lock assembly.
(d) Using a "TORX" socket wrench (T30), install the front door lock assembly with the 3 screws.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
15. INSTALL FRONT DOOR LOCK ASSEMBLY (w/ Power Door Lock)
NOTICE:
- When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
- Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
- Reusing the door lock wiring harness seal or using a damaged door lock wiring harness seal may cause water intrusion to the connection. This may result in a malfunction of the front door lock assembly.

(a) Apply MP grease to the sliding parts of the front door lock assembly.
(b) Install a new door lock wiring harness seal to the front door lock assembly.

(c) Insert the front door lock open rod to the front door lock assembly.
(d) Make sure that the front door lock open rod is securely connected to the front door lock assembly.
(e) Using a "TORX" socket wrench (T30), install the front door lock assembly with the 3 screws.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
16. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 2 claws to install the front door rear outside handle pad.
17. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the 2 claws to install the front door front outside handle pad.
18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY

(a) Insert the front end of the front door outside handle assembly into the front door outside handle frame.
(b) Insert the rear end of the front door outside handle assembly into the front door outside handle frame then slide the front door outside handle assembly toward the front of the vehicle to install it.
19. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)

(a) Engage the 2 claws to install the front door outside handle cover to the front door lock cylinder.

(b) Install the front door lock cylinder.
HINT: Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

(c) Using a "TORX" socket wrench (T30), install the front door lock cylinder with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
(d) Install the hole plug.
20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)
(a) w/o Power Door Lock:
HINT: Use the same procedures for the front passenger side and the driver side.

(b) w/ Power Door Lock:

(1) Using a "TORX" socket wrench (T30), install the front door lock cylinder with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
(2) Install the hole plug.
21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

(a) Install the front door rear lower frame sub-assembly with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
22. INSTALL FRONT DOOR GLASS RUN

(a) Install the front door glass run.
23. INSTALL FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY (w/ Power Window)
NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.

(a) Using a "TORX" socket wrench (T25), install the front power window regulator motor assembly with the 3 screws.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
HINT: The new front window regulator uses self-tapping screws to thread new installation holes.

24. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY (w/o Power Window)
(a) Apply MP grease to the sliding parts of the front door window regulator assembly.

(b) Install the front door window regulator assembly with the 5 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
25. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/ Power Window)
(a) Apply MP grease to the sliding parts of the front door window regulator sub-assembly.

(b) Install the temporary bolt to the front door window regulator sub-assembly.
(c) Temporarily install the front door window regulator sub-assembly.
(d) Tighten the temporary bolt and 5 bolts to install the front door window regulator sub-assembly.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Connect the connector.
26. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY

(a) Insert the front door glass sub-assembly into the front door panel along the front door glass run as shown in the illustration.

(b) Install the front door glass sub-assembly with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
27. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER

(a) Engage the claw, and install the outer rear view mirror assembly with cover.
(b) Aligning the threads and temporarily tighten the 3 screws by hand.
(c) Tighten the 3 screws.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
NOTE: If the specified torque cannot be obtained, replace the outer rear view mirror assembly with a new one.

(d) Connect the connector.
(e) Engage the clip.
28. INSTALL FRONT DOOR SERVICE HOLE COVER (w/o Power Door Lock)
(a) Apply butyl tape to the front door panel.
(b) Pass the front door lock remote control cable and rear door inside locking cable through a new front door service hole cover.

(c) Attach the front door service hole cover by using the reference points on the front door panel.
NOTE: Securely install the front door service hole cover preventing wrinkles and air bubbles.

29. INSTALL FRONT DOOR SERVICE HOLE COVER (w/ Power Door Lock)
(a) Apply butyl tape to the front door panel.
(b) Pass the front door lock remote control cable and rear door inside locking cable through a new front door service hole cover.

(c) Attach the front door service hole cover by using the reference points on the front door panel.
NOTE: Securely install the front door service hole cover preventing wrinkles and air bubbles.

(d) Connect the connector.
30. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY Installation
31. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP

(a) Install the front door inner glass weatherstrip.
32. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (w/o Front No. 2 Speaker)

(a) Engage the clip and clamp, and install the front door lower frame bracket garnish.
33. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (w/ Front No. 2 Speaker) Installation
34. INSTALL FRONT DOOR LOWER FRAME BRACKET GARNISH (w/ Front No. 2 Speaker)
(a) Connect the connector.

(b) Engage the clip and clamp, and install the front door lower frame bracket garnish.
35. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Connect the front door lock remote control cable and front door inside locking cable to the front door inside handle sub-assembly.

(b) Engage the 2 claws and install the front door inside handle sub-assembly.
36. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY

(a) Engage the front door trim board with the 5 claws on the front door inner glass weatherstrip.
(b) Engage the 10 clips and install the front door trim board sub-assembly to the front door panel.

(a) Install the power window regulator master switch assembly with the 3 screws.
38. INSTALL DOOR CONTROL SWITCH ASSEMBLY (for Front Passenger Side with Power Window)

(a) Engage the 2 claws and install the door control switch assembly.
39. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side with Power Window)

(a) Engage the 2 claws and install the power window regulator switch assembly.
40. INSTALL FRONT ARMREST UPPER BASE PANEL (w/o Power Window)

(a) Engage the clip and 7 claws, and install the front armrest upper base panel.
41. INSTALL FRONT ARMREST UPPER BASE PANEL (w/ Power Window)
(a) Connect the connector.

(b) Engage the clip and 7 claws, and install the front armrest upper base panel.
42. INSTALL FRONT DOOR INSIDE HANDLE BEZEL

(a) Engage the 3 claws and install the front door inside handle bezel.
43. INSTALL FRONT DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)
(a) Temporarily install the front door window regulator handle assembly and fully close the window glass.
(b) Install the front door regulator inside handle plate.
(c) Install the snap ring to the front door window regulator handle assembly.

(d) Install the front door window regulator handle assembly as shown in the illustration.
44. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL