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

  2. REMOVE REAR NO. 3 FLOOR BOARD


    1. Remove the rear No. 3 floor board.

  3. REMOVE DECK FLOOR BOX RH


    1. Fold back the rear No. 2 floor board.

    2. Remove the deck floor box RH Click here.

  4. REMOVE REAR NO. 3 FLOOR BOARD UPPER PLATE


    1. A0040W5

      Disengage the 2 claws and remove the rear No. 3 floor board upper plate.

  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  6. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG


    1. A00431H

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

  7. REMOVE ASSIST GRIP COVER


    1. A0041OM

      Using a moulding remover, disengage the 6 claws, 2 clips and 3 guides, and remove the assist grip cover.

  8. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY WITH FRONT DOOR ARMREST BASE PANEL (for Driver Side)


    1. A0043X4

      Disengage the 7 claws and 3 guides.

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

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


    1. A0042YA

      Disengage the 7 claws and 3 guides.

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

  10. REMOVE DOOR ARMREST COVER


    1. A0041MF

      Remove the door armrest cover.

  11. REMOVE COURTESY LIGHT ASSEMBLY


    1. A0043C2E02
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Using a moulding remover, disengage the claw.

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

  12. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A0041A7E02
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the front door panel.

    2. A0040IK

      Remove the 2 screws.

    3. Using a clip remover, disengage the 9 clips.

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

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

    6. A0042J4

      Disengage the 2 claws and disconnect the front door inside handle sub-assembly.

  13. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A0042WZ

      Disconnect the front door lock remote control cable and front door inside locking cable, and remove the front door inside handle sub-assembly.

  14. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A004312

      Disengage the 7 claws and remove the front door inner glass weatherstrip from the front door trim board sub-assembly as shown in the illustration.

  15. REMOVE OUTER MIRROR PROTECTOR


    1. A00432O

      Remove the screw.

    2. Disengage the 2 claws and remove the outer mirror protector.

  16. REMOVE OUTER MIRROR INSTALL HOLE COVER


    1. A00439V

      Disengage the 2 claws and guide, remove the outer mirror install hole cover.

  17. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY


    1. A0043QB

      Disconnect the connector.

    2. Remove the 3 bolts.

    3. Disengage the clip and remove the outer rear view mirror assembly.

  18. REMOVE DOOR FRAME GARNISH


    1. A00412H

      Disengage the clip and remove the door frame garnish.

      Tech Tips

      This garnish needs to be replaced with a new one because the clip will break when removing the door frame garnish.

  19. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY


    1. A0043PB

      Disconnect the connector.

    2. Using a drill bit with a diameter of less than 5 mm (0.197 in.), drill out the 4 rivet heads and remove the front No. 1 speaker assembly.

      Note


      • Do not touch the cone part of the speaker.

      • Do not drill the rivet at an angle as this will cause damage to the drill and drill hole. Line up the drill and rivet, and carefully drill out the rivet head.

      • Be careful as the cut rivet will be very hot.

    3. Continue drilling and push out the remaining rivet fragments.

    4. Using a vacuum cleaner, remove the rivet fragments and shavings from the inside of the door.

  20. REMOVE FRONT DOOR TRIM BRACKET


    1. A0041OZ

      Remove the 2 screws and front door trim bracket.

  21. REMOVE FRONT DOOR SERVICE HOLE COVER


    1. A0043FI

      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. A004472

      Remove the grommet.

    2. Connect the cable to the negative (-) auxiliary battery terminal and power window regulator master switch assembly.

    3. Move the front door glass sub-assembly so that the door glass bolts can be seen.

    4. Disconnect the cable from the negative (-) auxiliary battery terminal and power window regulator master switch assembly.

    5. A00428E

      Remove the 2 bolts.

      Note

      After the bolts are removed, do not allow the door glass to fall.

    6. A0042Y5E02

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

      Note

      Do not damage the door glass.

  23. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. A0043CVE01
      Text in Illustration
      *1 Temporary Bolt

      Disconnect the connector.

    2. Loosen the temporary bolt.

      Note

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

    3. Remove the 5 bolts.

    4. Remove the front door window regulator assembly.

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

  24. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY


    1. A00407U

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

  25. REMOVE FRONT DOOR STIFFENER CUSHION


    1. A0041VLE02
      Text in Illustration
      *1 Double-sided Tape

      Remove the 2 bolts and front door stiffener cushion.

  26. REMOVE FRONT DOOR GLASS RUN


    1. A0040EC

      Remove the front door glass run.

  27. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A0043TR

      Remove the bolt and front door rear lower frame sub-assembly as shown in the illustration.

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


    1. A00439F

      Remove the hole plug.

    2. A0041PR

      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. A0042U8

      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. A003ZZX

      Remove the hole plug.

    2. A0041J0

      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. w/ Entry and Start System:


      1. A00417F

        Disengage the 2 claws.

      2. Disconnect the connector.

    2. A00411K

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

    3. A0041HY

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

  32. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A0042A9

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

  33. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A0040DM

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

  34. REMOVE FRONT DOOR LOCK ASSEMBLY (w/o Double Locking System)


    1. A0043TT

      Disconnect the connector.

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

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

    4. A0042AL

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

  35. REMOVE FRONT DOOR LOCK ASSEMBLY (w/ Double Locking System)


    1. A00449V

      Disconnect the connector.

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

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

    4. A00400R

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

  36. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)


    1. A00435B

      Using a screwdriver, disengage the 7 claws as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A0043DM

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

  37. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)


    1. A00432J

      Using a screwdriver, disengage the 7 claws as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

    2. A00416Q

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

  38. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)


    1. A0040UX

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

  39. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)


    1. A0041OG

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

  40. REMOVE ELECTRICAL KEY WIRE HARNESS (w/ Entry and Start System)


    1. A0042DJ

      Disconnect the connector.

    2. Disengage the 4 clamps and remove the electrical key wire harness.

  41. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. A004059

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

    2. Slide the front door outside handle frame sub-assembly to disengage the door handle nut and claw of the front door outside handle frame sub-assembly, and then remove it.

  42. REMOVE FRONT DOOR LOCK OPEN ROD


    1. A00431ZE02

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

  43. REMOVE FRONT DOOR CHECK ASSEMBLY


    1. A0042VH

      Remove the 3 bolts and front door check assembly.

  44. REMOVE FRONT DOOR WEATHERSTRIP


    1. A0041D0

      Using a clip remover, disengage the 18 clips and remove the front door weatherstrip.

  45. REMOVE FRONT DOOR PANEL CUSHION


    1. A0040X6

      Disengage the 2 claws and remove the 2 front door panel cushions.

  46. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY


    1. A00448TE01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the front door belt moulding assembly.

    2. A0040NG

      Using a screwdriver, disengage the 7 claws and remove the front door belt moulding assembly.

  47. 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 front door rear window frame moulding moulding excessively.


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

    2. A004285E01
      Text in Illustration
      *1 Double-sided Tape

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

  48. REMOVE NO. 1 BLACK OUT TAPE


    1. Using a heat light, heat the No. 1 black out tape and vehicle body.

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

      Note

      Do not heat the vehicle body excessively.

    2. A0041U8

      Pull back on one of the ends of the No. 1 black out tape to remove it.

      Tech Tips

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

  49. REMOVE FRONT DOOR OUTSIDE STRIPE


    1. Using a heat light, heat the front door outside stripe and vehicle body.

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

      Note

      Do not heat the vehicle body excessively.

    2. A003ZZ6

      Pull back on one of the ends of the front door outside stripe to remove it.

      Tech Tips

      When pulling on the stripe, pull it parallel to the body.

  50. REMOVE FRONT DOOR LOWER OUTSIDE STRIPE


    1. Using a heat light, heat the front door lower outside stripe and vehicle body.

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

      Note

      Do not heat the vehicle body excessively.

    2. A0041GW

      Pull back on one of the ends of the front door lower outside stripe to remove it.

      Tech Tips

      When pulling on the stripe, pull it parallel to the body.

  51. REMOVE FRONT DOOR REAR OUTSIDE STRIPE


    1. Using a heat light, heat the front door rear outside stripe and vehicle body.

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

      Note

      Do not heat the vehicle body excessively.

    2. A00416R

      Pull back on one of the ends of the front door rear outside stripe to remove it.

      Tech Tips

      When pulling on the stripe, pull it parallel to the body.