FRONT DOOR DISASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Click here

  2. REMOVE DOOR ARMREST COVER


    1. A004HLEE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, disengage the 7 claws.

    2. Disengage the guides and remove the door armrest cover.

  3. REMOVE COURTESY LIGHT ASSEMBLY (w/ Courtesy Light)

    Click here

  4. REMOVE FRONT DOOR TRIM BOARD SUB-ASSEMBLY


    1. A004JFXE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, open the cap.

    2. A004IUU

      Using a clip remover, disengage the clip.

    3. Remove the 3 screws.

    4. A004J4P

      Using a moulding remover, disengage the 10 clips.

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

    6. Disconnect each connector.

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

    8. A004KX6E01
      Text in Illustration
      *1 Front Door Inside Locking Cable
      *2 Front Door Lock Remote Control Cable

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

  5. REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A004JB5E01

      Remove the 2 screws.

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

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


    1. A004KXN

      Remove the 4 screws and power window regulator master switch assembly with the front door armrest base panel.

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


    1. A004IGS

      Remove the 4 screws and power window regulator switch assembly with front door armrest base panel.

  8. REMOVE DOOR ASSIST GRIP ASSEMBLY


    1. A004KDX

      Remove the 2 screws.

    2. Disengage the guide and remove the door assist grip assembly.

  9. REMOVE FRONT LOWER DOOR TRIM PAD


    1. A004IRU

      Remove the front lower door trim pad with the 5 screws.

  10. REMOVE FRONT DOOR GLASS INNER WEATHERSTRIP


    1. Put a 4 mm (0.1575 in.) drill bit into a drill.

    2. Wind tape around the drill bit approximately 5 mm (0.1969 in.) from the tip of the drill, as shown in the illustration.

      Tech Tips

      Tape the 4 mm (0.1575 in.) drill bit to prevent the drill bit from going too deep.

      A004JQNE01
      Text in Illustration
      *1 Drill *2 Tape
      a 5.0 mm (0.1969 in.) - -

    3. Lightly press the drill against the 6 rivets and drill off the flanges of the 6 rivets.

      CAUTION:

      Take care with the drilled rivet as it may become hot.

      Note


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

      • Do not pry the rivet with the drill because this may cause damage to the installation holes of the rivet or the drill bit.

    4. A004JU4

      Disengage the 9 claws and remove the front door glass inner weatherstrip from the front door trim board sub-assembly, as shown in the illustration.

  11. REMOVE FRONT DOOR SPEAKER HOLE COVER (w/o Front Speaker)


    1. A004KKK

      Remove the front door speaker hole cover with the 3 screws.

  12. REMOVE FRONT NO. 1 SPEAKER ASSEMBLY (w/ Front Speaker)

    Click here

  13. REMOVE FRONT DOOR SERVICE HOLE COVER


    1. A004K8S

      Disconnect the outer rear view mirror sub-assembly connector.

    2. A004JJ2

      Disconnect the front door lock assembly connector.

    3. Remove the front door service hole cover.

      Tech Tips

      Remove any remaining butyl tape from the door.

  14. REMOVE OUTER REAR VIEW MIRROR SUB-ASSEMBLY

    Click here

  15. REMOVE FRONT DOOR GLASS SUB-ASSEMBLY

    A004HMR

    1. Provisionally install the power window regulator master switch (for driver side).

    2. Provisionally install the power window regulator switch (for passenger side).

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

    4. Move the front door glass sub-assembly until the 2 nuts can be seen through the service holes.

    5. Disconnect the power window regulator master switch connector (for driver side).

    6. Disconnect the power window regulator switch connector (for passenger side).

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

    8. A004II0

      Remove the 3 nuts.

    9. Shift the front door rear lower frame sub-assembly to the lower side of the door frame.

    10. A004HSLE03
      Text in Illustration
      *1 Door Glass Inner Stabilizer Bolt
      *2 Nut A
      *3 Nut B
      *4 Front Door Glass Sub-assembly
      *5 Front Door Window Regulator Sub-assembly
      *6 Bolt
      *a SST Number

      Install SST as shown in the illustration.

      SST
      09801-18010

      Tech Tips

      The SST number on SST must be visible.

    11. Secure the bolt using SST, and then remove nut A.

    12. Remove nut B from the front door glass sub-assembly.

    13. Loosen the door glass inner stabilizer bolt.

      Note

      After the 2 nuts are removed, do not allow the door glass to fall.

    14. A004HQ8

      While holding the front door glass sub-assembly up, slide the front door rear lower frame sub-assembly downward, and pull the front door glass sub-assembly out from the front door rear lower frame sub-assembly.

      Note


      • Do not allow the door glass to fall.

      • Do not damage the door glass.

    15. Partially remove the rear end of the front door weatherstrip until the front door glass sub-assembly can be removed.

    16. A004KCU

      Remove the front door glass sub-assembly from the position indicated in the illustration.

      Note

      Do not damage the front door weatherstrip.

      Tech Tips

      The front glass sub-assembly can only be removed from the position indicated in the illustration.

  16. REMOVE FRONT DOOR REAR LOWER FRAME SUB-ASSEMBLY


    1. Remove the front door rear lower frame sub-assembly from the front door frame.

  17. REMOVE DOOR GLASS INNER STABILIZER


    1. Remove the bolt and the door glass inner stabilizer.

  18. REMOVE FRONT DOOR SUSH


    1. A004KUC

      Remove the 3 nuts.

    2. A004KWIE01

      Rotate the front door sush as indicated by the arrows in the order shown in the illustration, and remove the front door sush.

      Note


      • Since the front door sush attachment bolts interfere, be sure to follow the procedure shown in the illustration.

      • Do not allow the front door sush to fall.

      • Do not damage the front door sush.

  19. REMOVE FRONT DOOR SASH STOPPER


    1. Remove the nut and front door sush stopper.

  20. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSEMBLY


    1. A004HRPE01
      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 sub-assembly may fall and cause damage.

    3. Remove the 3 bolts and 2 nuts.

    4. Remove the temporary bolt and the front door window regulator sub-assembly with power window regulator motor assembly.

  21. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Click here

  22. REMOVE FRONT DOOR WEATHERSTRIP


    1. Disengage the 2 claws and remove the screw.

    2. Using a clip remover, disengage the 16 clips and remove the front door weatherstrip.

      A004HPQ

  23. REMOVE FRONT DOOR LOCK CYLINDER ASSEMBLY (for Driver Side)


    1. A004IHJ

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

      Tech Tips

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

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


    1. A004HY4

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

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


    1. A004I9K

      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.

  26. REMOVE FRONT DOOR LOCK ASSEMBLY

    Click here

  27. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/o Entry and Start System)


    1. A004IQV

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

  28. REMOVE FRONT DOOR OUTSIDE HANDLE ASSEMBLY (w/ Entry and Start System)


    1. A004IDY

      Disengage the clamp.

    2. A004HTHE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws.

    3. Disconnect the connector.

    4. A004IQV

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

  29. REMOVE FRONT DOOR FRONT OUTSIDE HANDLE PAD


    1. A004HLI

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

  30. REMOVE FRONT DOOR REAR OUTSIDE HANDLE PAD


    1. A004K9T

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

  31. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. A004KKJE01
      Text in Illustration
      *a Outside Vehicle
      *b Inside Vehicle

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

    2. 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.

  32. REMOVE FRONT DOOR LOCK OPEN ROD


    1. A004KNCE01

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

  33. REMOVE FRONT DOOR CHECK ASSEMBLY


    1. A004K9G

      Remove the bolt.

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

  34. REMOVE FRONT DOOR PANEL CUSHION


    1. A004K6W

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

  35. REMOVE FRONT DOOR GLASS OUTER WEATHERSTRIP ASSEMBLY

    Click here

  36. REMOVE DOOR SIDE AIR BAG SENSOR

    Click here

  37. REMOVE FRONT DOOR HOLE COVER


    1. A004H96

      Disengage the 4 claws and remove the front door hole cover.