FRONT DOOR REASSEMBLY


  1. 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 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 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 falls off easily. When the temperature is high, the tape loses elasticity.

    3. Before installation


      1. Remove any roughness of coating and 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 level.

        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 3 to 7 cm (1.18 to 2.76 in.) per second.

        A003SLVE02
        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 - -

        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. A003TU3E09
        Text in Illustration
        *1 Squeegee
        *2 Hem
        *a First
        *b Second
        *c Third

        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.

        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.

  2. INSTALL NO. 2 BLACK OUT TAPE


    1. A003SKHE01

      Refer to the illustration to position the No. 2 black out tape.

      Reference measurement
      Area Measurement
      A 2 to 4 mm (0.078 to 0.158 in.)
      B 5 mm (0.197 in.)

    2. Remove the release paper and apply the tape.

  3. INSTALL NO. 1 BLACK OUT TAPE


    1. A003TRSE01

      Refer to the illustration to position the No. 1 black out tape.

      Reference measurement
      Area Measurement
      A 2 to 4 mm (0.078 to 0.158 in.)
      B 5 mm (0.197 in.)
      C 2 mm (0.078 in.)

    2. Remove the release paper and apply the tape.

      Note

      Be sure to install the No. 2 black out tape after applying the No. 1 black out tape.

  4. INSTALL FRONT DOOR BELT MOULDING ASSEMBLY


    1. Engage the 5 claws and clip, and install the front door belt moulding assembly.

  5. INSTALL FRONT DOOR PANEL CUSHION


    1. A003RKR

      Engage the 4 claws and install 2 new front door panel cushions.

  6. INSTALL FRONT DOOR WEATHERSTRIP


    1. A003RSX

      Engage the 16 clips and install the front door weatherstrip.

  7. INSTALL FRONT DOOR CHECK ASSEMBLY


    1. A003UL5

      Install the front door check assembly with the bolt and 2 nuts.

      Torque:
      Bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  8. INSTALL DOOR ELECTRICAL KEY OSCILLATOR (w/ Entry Function)


    1. Install the door electrical key oscillator with the screw.

  9. INSTALL FRONT DOOR LOCK OPEN ROD


    1. A003S4WE01

      Install the front door lock open rod as shown in the illustration.

  10. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/o Entry Function)


    1. Apply MP grease to the sliding parts of the front door outside handle frame sub-assembly.

    2. A003T57E01
      Text in Illustration
      *1 Grommet

      Engage the claw and grommet.

    3. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  11. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY (w/ Entry Function)


    1. Apply MP grease to the sliding parts on the front door outside handle frame sub-assembly.

    2. A003URDE01
      Text in Illustration
      *1 Grommet

      Engage the claw (A) and grommet.

    3. Using a T30 "TORX" socket wrench, install the front door outside handle frame sub-assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    4. Engage the claw (B).

    5. Connect the connector.

  12. INSTALL FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A003RQB

      Install the front door inside locking cable assembly.

    2. A003S20

      Engage the 3 claws.

  13. INSTALL FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A003TWS

      Install the front door lock remote control cable assembly.

  14. INSTALL FRONT DOOR LOCK ASSEMBLY

    Note


    • 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.


    1. Apply MP grease to the sliding parts of the front door lock assembly.

    2. Install a new door lock wiring harness seal to the front door lock assembly.

    3. A003T60

      Insert the front door lock open rod to the front door lock assembly.

    4. Make sure that the front door lock open rod is securely connected to the front door lock assembly.

    5. Using a T30 "TORX" socket wrench, install the front door lock assembly with the 3 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  15. INSTALL FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A003UGM

      Engage the 2 claws to install the front door rear outside handle pad.

  16. INSTALL FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A003UMM

      Engage the 2 claws to install the front door front outside handle pad.

  17. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Entry Function)


    1. A003SCZ

      Insert the front end of the front door outside handle assembly into the front door outside handle frame.

    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Next, slide the front door outside handle assembly toward the front of the vehicle to install it.

  18. INSTALL FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Entry Function)


    1. A003S89

      Insert the front end of the front door outside handle assembly into the front door outside handle frame.

    2. Insert the rear end of the front door outside handle assembly into the front door outside handle frame. Next, slide the front door outside handle assembly toward the front of the vehicle to install it.

    3. A003SKN

      Connect the connector.

  19. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Driver Side)


    1. A003UWF

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

    2. A003U8A

      Install the front door lock cylinder.

      Tech Tips

      Make sure that the front door lock cylinder rod is inserted into the front door lock assembly.

    3. A003UAQ

      Using a T30 "TORX" socket wrench, install the front door lock cylinder with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    4. Install the hole plug.

  20. INSTALL FRONT DOOR OUTSIDE HANDLE COVER (for Front Passenger Side)


    1. A003TWH

      Using a T30 "TORX" socket wrench, install the front door outside handle cover with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install the hole plug.

  21. INSTALL FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. A003RPU

      Install the front door rear lower frame sub-assembly with the bolt.

  22. INSTALL DOOR FRAME GARNISH


    1. A003RTA

      Engage the clip and install a new door frame garnish.

  23. INSTALL FRONT DOOR GLASS RUN


    1. A003TCB

      Install the front door glass run.

  24. INSTALL FRONT DOOR NO. 2 STIFFENER CUSHION


    1. A003RL8

      Insert the guide and install the front door No. 2 stiffener cushion with the bolt.

  25. INSTALL FRONT DOOR WINDOW REGULATOR ASSEMBLY


    1. Apply MP grease to the sliding parts of the front door window regulator assembly.

    2. A003SHGE02
      Text in Illustration
      *1 Temporary Bolt

      Install the temporary bolt to the front door window regulator assembly.

    3. Temporarily install the front door window regulator assembly.

    4. Tighten the temporary bolt and 5 bolts to install the front door window regulator assembly.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    5. Connect the connector.

  26. INSTALL FRONT DOOR GLASS SUB-ASSEMBLY


    1. A003S0IE01

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

    2. A003TNQ

      Install the front door glass sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  27. INSTALL OUTER REAR VIEW MIRROR ASSEMBLY WITH COVER


    1. Engage the claw, and temporarily install the outer rear view mirror assembly with cover.

    2. Install the 3 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    3. Connect the connector.

  28. INSTALL OUTER MIRROR INSTALL HOLE COVER


    1. Engage the guide and the 3 claws, and install the outer mirror install hole cover.

  29. INSTALL FRONT DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the front door panel.

    2. Pass the front door lock remote control cable and rear door inside locking cable through a new front door service hole cover.

    3. A003TJBE02
      Text in Illustration
      *1 Reference Point

      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 avoiding wrinkles and air bubbles.

    4. Connect the connector.

  30. INSTALL FRONT NO. 1 SPEAKER ASSEMBLY


    1. Using an air riveter or hand riveter, install the front No. 1 speaker assembly with 3 new rivets.

      A003SPFE02
      Text in Illustration
      *1 Riveter *2 Mandrel
      *a INCORRECT - -

      Note


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

      • Confirm that the rivet is 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.

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

      Tech Tips

      If the rivet cannot be cut, pull it once and cut it.

    2. A003UAW

      Connect the connector.

  31. INSTALL FRONT DOOR INNER GLASS WEATHERSTRIP


    1. A003U7T

      Install the front door inner glass weatherstrip.

  32. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY


    1. Engage the 3 claws and install the front No. 2 speaker assembly.

  33. INSTALL POWER WINDOW REGULATOR MASTER SWITCH ASSEMBLY (for Driver Side)


    1. A003SFU

      Install the power window regulator master switch assembly with the 3 screws.

  34. INSTALL POWER WINDOW REGULATOR SWITCH ASSEMBLY (for Front Passenger Side)


    1. A003T8U

      Engage the 2 claws and install the power window regulator switch assembly.

  35. INSTALL FRONT ARMREST BASE PANEL UPPER


    1. A003UQ1

      Engage the 7 claws and install the front armrest base panel upper.

  36. INSTALL FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A003T8I

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

    2. A003SJL

      Engage the 2 claws and install the front door inside handle sub-assembly.

  37. INSTALL FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. Connect each connector.

    2. A003SYF

      Engage the front door trim board with the 4 claws on the front door inner glass weatherstrip.

    3. Engage the 9 clips and install the front door trim board to the front door panel.

    4. A003T3P

      Install the 3 screws.

  38. INSTALL DOOR ASSIST GRIP COVER


    1. A003RR8

      Engage the 4 claws and install the door assist grip cover.

  39. INSTALL FRONT DOOR INSIDE HANDLE BEZEL


    1. A003RQF

      Engage the 3 claws and install the front door inside handle bezel.

  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  41. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  42. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  43. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.

  44. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here