FRONT DOOR REASSEMBLY

REPAIR INSTRUCTION

1. Clean the vehicle body surface.

   1. Using a heat light, heat the vehicle body surface.

      Heating Temperature

      Item	Temperature
      Vehicle Body	40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

   2. Wipe off any tape adhesive residue with cleaner.

2. Installation temperature

   1. When the ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When the ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.

      Tech Tips

      • The most appropriate temperature for installing the tape is 25°C (77°F).

      • When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape elasticity increases.

3. Before installation

   1. Remove any coating roughness or dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.

      Tech Tips

      Spray water on the shop floor to settle any dust.

4. Key points for handling the tape

   1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and flat.

      Note

      Do not bend the tape or leave it in high temperature places.

5. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)

   Note

   • Position the tape accurately to achieve a neat finish and to avoid peeling.

   • The tape cannot be reused because it deforms and will not fit any more after being removed.

   1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at 40 to 50° (pressing forward) or 30 to 45° (pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf, 4.5 to 6.7 lbf) at a constant slow speed of 30 to 70 mm (1.18 to 2.76 in.) per second.

      

      Text in Illustration

      *A	Pressing Forward	*B	Pulling
      *1	Non-padded Side	*2	Padded Side
      *3	Squeegee	*4	Black Out Tape
      *5	Release Paper	-	-
      *a	Side View	-	-

      Reference Measurement

      Area	Measurement
      A	10 to 20 mm (0.393 to 0.787 in.)
      B	30 to 70 mm/sec. (1.18 to 2.76 in./sec.)
      C	40 to 50° (for pressing forward)
      D	30 to 45° (for pulling)

      Note

      Be sure to observe the specified pressing speed, force and angle of the squeegee to avoid wrinkles or air bubbles.

      Tech Tips

      • Either angle of the squeegee (pressing forward or pulling) is acceptable.

      • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 to 0.787 in.) from the edge of the squeegee.

6. Key points for installation of the tape (how to use a squeegee and installation procedure for hemmed surfaces)

   1. If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.

      

      Text in Illustration

      *1	Squeegee
      *2	Hem
      *a	First
      *b	Second
      *c	Third

      Tech Tips

      When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

7. Key points for installation of the tape (how to use a squeegee and installation procedure for corners)

   1. Remove the release paper and apply the tape carefully with your fingers.

   2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.

8. Check after installation

   1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.

      Note

      Do not reuse the tape.

INSTALL FRONT DOOR LOWER OUTSIDE STRIPE

1. Refer to the illustration to position the front door lower outside stripe.

   

   Text in Illustration

   *A	LH Side	*B	RH Side
   *a	Edge of Curved Surface	*b	Square
   *c	Round	-	-

   Standard Measurement

   Dimension	Measurement
   A	1.5 mm (0.0591 in.)
   B	1.0 mm (0.0394 in.)

2. Remove the release paper and apply the stripe.

INSTALL FRONT DOOR STRIPE

1. Refer to the illustration to position a new front door stripe.

   

   Text in Illustration

   *A	LH Side	*B	RH Side
   *a	Edge of Curved Surface	*b	Square
   *c	Round	-	-

   Standard Measurement

   Dimension	Measurement
   A	1.5 mm (0.0591 in.)
   B	1.0 mm (0.0394 in.)

2. Remove the release paper and apply the stripe.

INSTALL FRONT DOOR UPPER WINDOW FRAME MOULDING

1. Engage the claw and guide of the front door upper window frame moulding to the door frame.

   

2. Using an air riveter or hand riveter with a nose piece, install the front door upper window frame moulding with 7 new rivets.

   Tech Tips

   If the mandrel of the rivet does not come off on the first operation of the rivet gun, slide the rivet gun forward on the mandrel and operate it again.

   Note

   • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

     

     Text in Illustration

     *1	Riveter
     *2	Mandrel
     *a	Incorrect

   • Confirm that the rivets are seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding.

     

     Text in Illustration

     *1	Riveter
     *a	Incorrect

   • Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

     

     Text in Illustration

     *1	Riveter
     *a	Incorrect

INSTALL FRONT DOOR REAR WINDOW FRAME MOULDING

1. Clean the vehicle body surface.

   1. Using a heat light, heat the vehicle body surface.

   2. Remove the double-sided tape from the vehicle body.

   3. Wipe off any tape adhesive residue with cleaner.

2. Install a new front door rear window frame moulding.

   

   Text in Illustration

   *1	Double-sided Tape
   *2	Caulking Sponge

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

   2. Remove the release paper from the face of the front door rear window frame moulding.

      Tech Tips

      After removing the release paper, keep the exposed adhesive free from foreign matter.

   3. Install the front door rear window frame moulding with the clip.

INSTALL FRONT DOOR BELT MOULDING ASSEMBLY

1. Engage the 6 claws to install the front door belt moulding assembly.

   

INSTALL DOOR SIDE AIRBAG SENSOR

1. Check that the ignition switch is off.

2. Check that the cable is disconnected from the negative (-) battery terminal.

   CAUTION:

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

3. Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

   

   Text in Illustration

   *a

   Incorrect

   *b

   Correct

4. Insert the pin (stopper) into the door hole and install the door side airbag sensor to the front door panel with the bolt.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

   Note

   • If the door side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one.

   • When installing the door side airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts.

   • Make sure that the pin (stopper) is securely inserted into the body hole.

   • Tighten the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.

5. Connect the connector to the door side airbag sensor.

   Note

   When connecting any airbag connector, take care not to damage the airbag wire harness.

   1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).

      

      Text in Illustration

      *1	White Housing Lock	*2	Yellow CPA
      *a	Connection is Completed	-	-

      Tech Tips

      When engaged, the white housing lock will slide. Be sure not to hold the white housing lock and part (A), as it may result in an insecure fit.

6. Check that there is no looseness in the installation parts of the door side airbag sensor.

INSTALL OUTER REAR VIEW MIRROR ASSEMBLY

1. Engage the claw to temporarily install the outer rear view mirror assembly.

2. Install the outer rear view mirror assembly with the 3 bolts.

   Torque:

   11 N*m  { 107 kgf*cm, 8 ft.*lbf }

3. Connect the connector.

INSTALL FRONT NO. 1 SPEAKER ASSEMBLY

1. Engage the 2 claws to the vehicle body to temporarily install the front No. 1 speaker assembly.

2. Install the front No. 1 speaker assembly with the 4 screws.

   

   *A	LH Side
   *B	RH Side

   Note

   Do not touch the speaker cone.

   Tech Tips

   Install the screws in the order shown in the illustration.

3. Connect the connector.

INSTALL COURTESY LIGHT ASSEMBLY

1. Connect the connector.

2. Engage the claw to install the courtesy light assembly.

   

   Text in Illustration

   *A	for LH Side
   *B	for RH Side