FRONT DOOR DISASSEMBLY

Tech Tips


  • Use the same procedure for both the RH and LH sides.

  • The procedure described below is for the LH side.


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A01G4MY

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

  4. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)


    1. A01G55U

      Using a moulding remover, disengage the 2 clips, 6 claws and 2 guides as shown in the illustration.

    2. Disconnect each connector and remove the multiplex network master switch assembly with front door armrest base panel.

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


    1. A01G72A

      Using a moulding remover, disengage the 2 clips, 6 claws and 2 guides as shown in the illustration.

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

  6. REMOVE DOOR PULL HANDLE COVER


    1. A01G53E

      Remove the door pull handle cover.

  7. REMOVE COURTESY LIGHT ASSEMBLY


    1. A01G6KGE01
      Text in Illustration
      *A for LH Side
      *B for RH Side
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, disengage the claw.

    2. Disconnect the connector and remove the courtesy light assembly.

  8. REMOVE FRONT DOOR NO. 1 STIFFENER CUSHION


    1. A01G98H

      Remove the screw and front door No. 1 stiffener cushion.

  9. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A01G517E01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the front door panel.

    2. A01G7VV

      Remove the 3 screws.

    3. A01G6RQ

      Using a clip remover, disengage the 11 clips.

    4. A01G7HME01
      Text in Illustration
      *1 Reference Boss
      *2 Front Door Inner Glass Weatherstrip

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

    5. Disengage the reference boss from the front door panel.

    6. Raise the front door trim board sub-assembly and disconnect the front door trim board sub-assembly together with the front door inner glass weatherstrip.

    7. w/ Memory:


      1. Disconnect the connector.

    8. w/ Illumination:


      1. Disconnect the connector.

    9. A01G5K5

      Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly to remove the front door trim board sub-assembly together with the front door inner glass weatherstrip.

  10. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A01G7XDE01
      Text in Illustration
      *1 Screwdriver

      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.

  11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A01G8LL

      Disengage the claw and 2 guides, and remove the front door inside handle sub-assembly.

  12. REMOVE SEAT MEMORY SWITCH (w/ Memory)


    1. A01G7JB

      Disengage the 4 claws to remove the seat memory switch from the front door trim board sub-assembly.

  13. REMOVE FRONT DOOR TRIM ORNAMENT SUB-ASSEMBLY (for Wood Panel and Bamboo Panel)


    1. w/ Illumination:


      1. A01G53A

        Disengage the 3 clamps.

    2. A01G59A

      Remove the 11 screws and front door trim ornament assembly.

    3. A01G7A0

      Remove the screw.

    4. Disengage the claw and remove the front door trim ornament sub-assembly.

  14. REMOVE OUTER MIRROR CONTROL ECU ASSEMBLY (w/ Memory)


    1. Disconnect 2 connectors.

    2. A01G81S

      Remove the 2 screws and outer mirror control ECU assembly.

  15. REMOVE OUTER MIRROR PROTECTOR


    1. A01G4Z2

      Remove the outer mirror protector.

  16. REMOVE OUTER MIRROR INSTALL HOLE COVER


    1. w/o Memory:


      1. A01G888

        Disconnect the connector.

    2. A01G7VC

      Remove the screw.

    3. A01G7Z6E01

      Disengage the claw<A> as shown in the illustration.

    4. Disengage the claw<B> and remove the outer mirror install hole cover as shown in the illustration.

  17. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY


    1. A01G9GZ

      Remove the 3 nuts.

    2. Disengage the clamp and remove the outer rear view mirror assembly.

  18. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH


    1. A01G64Z

      Disengage the 2 clips and remove the front door lower frame bracket garnish.

  19. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY


    1. A01G4HN

      Disconnect the connector.

    2. Remove the 4 screws and front No. 1 speaker assembly.

      Note

      Do not touch the speaker cone.

  20. REMOVE FRONT DOOR ARMREST SET BRACKET


    1. A01G4GM

      Remove the 2 screws and front door armrest set bracket.

  21. REMOVE FRONT DOOR SERVICE HOLE COVER


    1. A01G7I8E01
      Text in Illustration
      *A for LH Side

      Disconnect the 2 connectors.

    2. Disengage each clamp.

    3. A01G5ST

      Remove the front door service hole cover.

      Tech Tips

      Remove any remaining butyl tape from the door.

  22. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY


    1. A01G6B1

      Remove the grommet.

    2. Connect the cable to the negative (-) battery terminal.

    3. Connect the multiplex network master switch assembly and move the front door glass sub-assembly so that the door glass bolts can be seen.

    4. Disconnect the cable from the negative (-) battery terminal.

    5. Disconnect the multiplex network master switch assembly.

    6. A01G599

      Remove the 2 bolts.

      Note

      After the bolts are removed, do not allow the front door glass sub-assembly to fall.

    7. A01G5SVE01

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

      Note

      Do not damage the front door glass sub-assembly.

  23. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. A01G8F8E01
      Text in Illustration
      *1 Temporary Bolt

      Loosen the temporary bolt.

      Note

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

    2. Remove the 5 bolts.

    3. Remove the front door window regulator assembly.

    4. Remove the temporary bolt from the front door window regulator assembly.

  24. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY


    1. A01G77U

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

  25. REMOVE FRONT DOOR GLASS RUN


    1. A01G6RJ

      Remove the front door glass run.

  26. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY


    1. A01G8RM

      Remove the 2 bolts.

    2. Disengage the guide and remove the front door front lower frame sub-assembly.

  27. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A01G8NJ

      Remove the bolt.

    2. Disengage the guide and remove the front door rear lower frame sub-assembly.

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


    1. A01G5N9

      Remove the hole plug.

    2. A01G7QE

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

      Tech Tips

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

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


    1. A01G5NF

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

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


    1. A01G8XI

      Remove the hole plug.

    2. A01G5ID

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

      Tech Tips

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

  31. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY


    1. A01G5VI

      Disengage the 2 claws.

    2. Using a screwdriver, disconnect the connector.

    3. A01G64W

      Move the lever in the direction indicated by the arrow in the illustration.

    4. A01G6KQ

      Remove the front door outside handle assembly as shown in the illustration.

  32. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A01G7BC

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

  33. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A01G4HT

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

  34. REMOVE FRONT DOOR LOCK ASSEMBLY


    1. A01G6HUE01
      Text in Illustration
      *1 Front Door Lock Open Rod

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

    2. Slide the front door lock assembly downward, and remove the front door lock assembly and cables as a unit.

    3. When reusing the front door lock assembly:


      1. A01G9RR

        Remove the door lock wiring harness seal from the front door lock assembly.

  35. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A01G9RY

      Remove the front door lock remote control cable assembly as shown in the illustration.

  36. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A01G7E8

      Using a screwdriver, disengage the 3 claws as shown in the illustration.

    2. A01G5SN

      Remove the front door inside locking cable assembly as shown in the illustration.

  37. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. A01G4CG

      Disengage the 3 clamps.

    2. A01G8BQE01
      Text in Illustration
      *a Outside
      *b Inside

      Using a T30 "TORX" socket wrench, loosen the screw.

    3. 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.

  38. REMOVE FRONT DOOR LOCK OPEN ROD


    1. A01G4J4E01

      Remove the front door lock open rod as indicated by the arrows and in the order shown in the illustration.

  39. REMOVE FRONT DOOR NO. 2 STIFFENER CUSHION


    1. A01G4KHE02
      Text in Illustration
      *1 Double-sided Tape

      Remove the 2 bolts.

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

  40. REMOVE FRONT DOOR CHECK ASSEMBLY


    1. A01G9GSE01
      Text in Illustration
      *1 Bolt
      *2 Nut

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

  41. REMOVE FRONT DOOR WEATHERSTRIP


    1. A01G528E01
      Text in Illustration
      *1 Double-sided Tape

      Using a clip remover, disengage the 21 clips and guide, and remove the front door weatherstrip.

  42. REMOVE DOOR FRAME GARNISH


    1. A01G6UB

      Disengage the 3 claws and remove the door frame garnish.

  43. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP


    1. A01G6DQ

      Using a clip remover, disengage the 9 clips and remove the front door No. 2 weatherstrip.

  44. REMOVE FRONT DOOR PANEL CUSHION


    1. A01G785

      Disengage the claw and remove the front door panel cushion.

  45. REMOVE FRONT DOOR LOWER FRAME GARNISH PAD


    1. A01G9A5

      Remove the front door lower frame garnish pad.

  46. REMOVE FRONT DOOR FRONT LOWER FRAME UPPER COVER


    1. A01G5TB

      Remove the nut and front door front lower frame upper cover.

  47. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY


    1. A01G9EJE01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the front door belt moulding assembly.

    2. Using a screwdriver with the tip wrapped with protective tape, disengage the 6 claws and guide and remove the front door belt moulding assembly.

  48. REMOVE FRONT DOOR REAR WINDOW FRAME MOULDING

    Tech Tips

    When removing the front door rear window frame moulding, heat the vehicle body and front door rear window frame moulding using a heat light.

    Heating Temperature
    Item Temperature
    Vehicle Body 40 to 60°C (104 to 140°F)
    Moulding 20 to 30°C (68 to 86°F)

    Note

    Do not heat the vehicle body or moulding excessively.


    1. Using a heat light, heat the front door rear window frame moulding.

    2. A01G710E01
      Text in Illustration
      *1 Double-sided Tape
      *2 Caulking Sponge

      Using a moulding remover, disengage the clip and guide and remove the front door rear window frame moulding.

  49. REMOVE FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY


    1. Insert a 4.0 mm (0.157 in.) drill bit into a drill.

    2. Tape the 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration.

      A01G6XOE01
      Area Dimension
      A 5.0 mm (0.197 in.)

      Note

      Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

    3. Lightly press the drill against the rivets to drill off the rivet flanges, and remove the 7 rivets.

      Note


      • Pressing the drill too firmly will cause the rivet to turn and result in the rivet not being drilled through.

      • Prying the rivets with the drill may damage the rivet installation holes or drill bit.

      • Be careful of the drilled rivets, as they may be hot.

    4. Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas.

    5. Disengage the guide and remove the front door outside moulding sub-assembly.

  50. REMOVE FRONT DOOR REAR INNER BLACK OUT TAPE


    1. Using a heat light, heat the front door rear inner black out tape and vehicle body.

      Heating Temperature
      Item Temperature
      Vehicle Body and Front Door Rear Inner Black Out Tape 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A01G8VL

      Pull back on one of the ends of the front door rear inner black out tape to remove it.

      Tech Tips

      When pulling on the black out tape, pull it parallel to the body.

  51. REMOVE FRONT INNER BLACK OUT TAPE


    1. Using a heat light, heat the front inner black out tape and vehicle body.

      Heating Temperature
      Item Temperature
      Vehicle Body and Front Inner Black Out Tape 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

    2. A01G8DO

      Pull back on one of the ends of the front inner black out tape to remove it.

      Tech Tips

      When pulling on the black out tape, pull it parallel to the body.