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 LUGGAGE TRIM SERVICE HOLE COVER

    1. Disengage the claw to remove the luggage trim service hole cover.

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  3. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

    CAUTION:

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

    Note

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

  4. REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG

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

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  5. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH

    1. Disengage the 3 clips and remove the front door lower frame bracket garnish.

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

    1. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

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

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

    1. Using a moulding remover, disengage the 2 clips, 5 claws and 4 guides as shown in the illustration.

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

  8. REMOVE FRONT ARMREST ASSEMBLY

    1. Using a moulding remover, disengage the 3 clips, 7 claws and 2 guides and remove the front armrest assembly.

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  9. REMOVE COURTESY LIGHT ASSEMBLY

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

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

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

  10. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY

    1. Put protective tape around the front door panel.

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      Text in Illustration
      *1 Protective Tape

    2. Remove the 3 screws.

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    3. Using a clip remover, disengage the 10 clips.

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

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

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

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

    7. Disconnect the front door lock remote control cable assembly and front door inside locking cable assembly.

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  11. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY

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

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  12. REMOVE FRONT DOOR INNER GLASS WEATHERSTRIP

    1. 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.

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      Text in Illustration
      *1 Screwdriver

  13. REMOVE DOOR SIDE AIRBAG SENSOR

    1. Check that the power switch is off.

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

      CAUTION:

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

    3. Disconnect the connector from the door side airbag sensor.

      Note

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

      1. Push down the white housing lock and slide the yellow CPA. (At this time, the connector cannot be disconnected yet.)

        A011YLJE12
        Text in Illustration
        *1 White Housing Lock *2 Yellow CPA
        *a Connector Lock is Released - -

      2. Push down the white housing lock again and disconnect the connector.

        Note

        Do not push down the part (A) shown in the illustration when disconnecting the connector.

    4. Remove the bolt and door side airbag sensor from the front door panel.

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      Note

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

    5. After disconnecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

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      Text in Illustration
      *a Incorrect *b Correct

  14. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY

    1. Disconnect the connector.

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    2. Remove the 4 screws.

    3. Disengage the 2 claws and remove the front No. 1 speaker assembly.

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      Note

      Do not touch the speaker cone.

  15. REMOVE OUTER REAR VIEW MIRROR ASSEMBLY

    1. Disconnect the connector.

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    2. Remove the 3 bolts.

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

  16. REMOVE FRONT DOOR SERVICE HOLE COVER

    1. Remove the bolt.

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    2. Disconnect each connector.

    3. Disengage the 5 clamps.

    4. Remove the front door service hole cover.

      Tech Tips

      Remove any remaining butyl tape from the door.

  17. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY

    1. Remove the grommet.

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

    3. Connect the power window regulator 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 (-) auxiliary battery terminal.

      CAUTION:

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

      Note

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

    5. Disconnect the power window regulator master switch assembly.

    6. Remove the 2 bolts.

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      Note

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

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

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      Note

      Do not damage the door glass.

  18. REMOVE FRONT DOOR WINDOW REGULATOR ASSEMBLY

    1. Loosen the temporary bolt.

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      Text in Illustration
      *1 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.

    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.

  19. REMOVE FRONT POWER WINDOW REGULATOR MOTOR ASSEMBLY

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

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  20. REMOVE NO. 2 FRONT DOOR STIFFENER CUSHION

    1. Remove the 2 bolts.

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      Text in Illustration
      *1 Double-sided Tape

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

  21. REMOVE FRONT DOOR GLASS RUN

    1. Remove the front door glass run.

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  22. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

    1. Remove the 2 bolts.

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    2. Disengage the guide and remove the front door front lower frame sub-assembly as shown in the illustration.

  23. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY

    1. Remove the 2 bolts.

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    2. Disengage the guide and remove the front door rear lower frame sub-assembly as shown in the illustration.

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

    1. Remove the hole plug.

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

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      Tech Tips

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

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

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

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

    1. Remove the hole plug.

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

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      Tech Tips

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

  27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY

    1. Disengage the 2 claws.

    2. Using a screwdriver, disconnect the connector.

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

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  28. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD

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

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  29. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD

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

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  30. REMOVE FRONT DOOR LOCK WITH MOTOR ASSEMBLY

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

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      Text in Illustration
      *1 Front Door Lock Open Rod

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

    3. When reusing the front door lock with motor assembly:

      1. Remove the door lock wiring harness seal from the front door lock with motor assembly.

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  31. REMOVE FRONT DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

    1. Remove the front door lock remote control cable assembly.

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  32. REMOVE FRONT DOOR INSIDE LOCKING CABLE ASSEMBLY

    1. Using a screwdriver, disengage the 3 claws.

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    2. Remove the front door inside locking cable assembly.

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  33. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

    1. Disconnect the connector.

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    2. Disengage the 3 clamps.

    3. Using a T30 "TORX" socket wrench, remove the screw and door handle nut.

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      Text in Illustration
      *1 Door Handle Nut
      *a Outside
      *b Inside

    4. 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.

  34. REMOVE FRONT DOOR WIRE

    1. Disengage the 3 clamps and remove the front door wire.

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  35. REMOVE FRONT DOOR LOCK OPEN ROD

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

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  36. REMOVE FRONT DOOR CHECK ASSEMBLY

    1. Remove the 3 bolts and front door check assembly.

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  37. REMOVE FRONT DOOR WEATHERSTRIP

    1. Using a clip remover, disengage the 19 clips and remove the front door weatherstrip.

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  38. REMOVE DOOR FRAME GARNISH

    1. Disengage the clip and remove the door frame garnish.

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      Tech Tips

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

  39. REMOVE FRONT DOOR NO. 2 WEATHERSTRIP

    1. Using a clip remover, disengage the 8 clips and remove the front door No. 2 weatherstrip.

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  40. REMOVE FRONT DOOR PANEL CUSHION

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

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  41. REMOVE DOOR DUST PROOF SEAL

    1. Remove the door dust proof seal.

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  42. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY

    1. Put protective tape around the front door belt moulding assembly.

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      Text in Illustration
      *1 Protective Tape

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

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      Text in Illustration
      *1 Protective Tape

      Tech Tips

      Tape the screwdriver tip before use.

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

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

  44. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING

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

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

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      Area Dimension
      A 5.0 mm

      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 claw and guide, and remove the front door upper window frame moulding from the door frame.

  45. REMOVE FRONT DOOR STRIPE

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

      Heating Temperature
      Item Temperature
      Vehicle Body and Front Door Outside Stripe 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

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

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      Tech Tips

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

  46. 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 and Front Door Rear Outside Stripe 40 to 60°C (104 to 140°F)

      Note

      Do not heat the vehicle body excessively.

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

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      Tech Tips

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