Front Door - Reassembly(2006/01 - 2007/12)

1. Repair instruction

2. Install front door lower outside stripe

3. Install front door stripe

4. Install front door upper window frame moulding

5. Install front door rear window frame moulding

6. Install front door belt moulding assembly

7. Install front door weatherstrip

8. Install front door check assembly

9. Install front door outside handle frame sub-assembly

10. Install front door inside locking cable assembly

11. Install front door lock remote control cable assembly

12. Install front door lock assembly

13. Install front door rear outside handle pad

14. Install front door front outside handle pad

15. Install front door outside handle assembly

16. Install front door outside handle cover

17. Install front door rear lower frame sub-assembly

18. Install front door front lower frame sub-assembly

19. Install door frame garnish

20. Install front door glass run

21. Install front no. 1 door stiffener cushion

22. Install front power window regulator motor assembly

23. Install front door window regulator sub-assembly

24. Install front door glass sub-assembly

25. Install front door service hole cover

26. Install outer rear view mirror assembly

27. Install front no. 1 speaker assembly

28. Install front door inner glass weatherstrip

29. Install front armrest base panel upper

30. Install front door wire (for driver side)

31. Install power window regulator master switch assembly

32. Install front door inside handle sub-assembly

33. Install front door trim board sub-assembly

34. Install courtesy light assembly

35. Install assist grip cover

36. Install front door inside handle bezel plug

37. Install front door lower frame bracket garnish

38. Initialize power window control system

​

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)

      NOTICE:

      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, 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 using a heat light. When ambient temperature is above 35°C, cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C prior to installation.

      HINT:

      1. The most appropriate temperature for installing the tape is 25°C.
         
      2. When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape looses 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.

      HINT:

      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.

      NOTICE:

      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)

   NOTICE:

   1. Conduct positioning of the tape with a high accuracy to achieve a neat finish and to avoid peeling.
      
   2. The tape cannot be reused because it deforms or does not fit any more after being removed.
      
   
   

   1. To avoid air bubbles, slightly raise the part of the tape that are going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at a 40 to 50° (for pressing forward) or 30 to 45° (for 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) at a constant slow speed of 3 to 7 cm per second.
      

      
      
      
      

      NOTICE:

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

      HINT:

      1. Either angle of the squeegee (for pressing forward or for pulling) is acceptable.
         
      2. Be sure to apply the tape while removing the release paper 10 to 20 mm from the edge of the squeegee.
         

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

   2. If it is difficult to press the tape, press 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.

      HINT:

      When applying the 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, to avoid wrinkles on the tape and 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.

      NOTICE:

      Do not reuse the tape.

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

   
   
   
   

2. Remove the release paper and apply the stripe.

NOTICE:

Be sure to install the front door stripe after applying the front door lower outside stripe.

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

   
   
   
   

2. Remove the release paper and apply the stripe.

1. Install 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.

   HINT:

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

   NOTICE:

   1. Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.
      
   2. 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.
      
   3. Do not leave any space between the moulding and door frame. Firmly hold together the 2 items while installing the rivet.
      

HINT:

When installing 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)

NOTICE:

Do not heat the vehicle body and front door window frame moulding excessively.

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. Clean the front door rear window frame moulding. (If reusing the front door rear window frame moulding)
   

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

   2. Remove the double-sided tape from the front door rear window frame moulding.

   3. Wipe off any tape adhesive residue with cleaner.

   4. Apply new double-sided tape to the front door rear window frame moulding.

3. Install the front door rear window frame moulding.
   

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

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

      HINT:

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

   4. Engage the clip and install the front door rear window frame moulding.

1. Engage the 2 clips and 5 claws, and install the front door belt moulding assembly.

1. Engage the 19 clips to install a new front door weatherstrip.

1. Install the front door check assembly with the 3 bolts.

   Torque:

   Bolt (A):

   26 N*m{265 kgf*cm, 19 ft.*lbf}

   Torque:

   Bolt (B):

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

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

2. Engage the claw to install the front door outside handle frame sub-assembly.

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

   Torque:

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

1. Install the front door inside locking cable assembly.

2. Engage the 3 claws.

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

NOTICE:

1. When reusing the removed front door lock assembly, replace the door lock wiring harness seal on the connector with a new one.
   
2. Do not allow grease or dust to adhere to the door lock wiring harness seal surface of the connector.
   
3. 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. Insert the front door lock open rod to the front door lock assembly, and set it to the front door outside handle frame.

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

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

   Torque:

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

6. Connect the connector.

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

1. Engage the 3 claws to install the front door front outside handle pad.

1. 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.

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

2. Install the front door lock cylinder.

   HINT:

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

3. Using a "TORX" socket wrench (T30), 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.

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

1. Install the front door front lower frame sub-assembly with the 2 bolts.

1. Engage the clip and install a new door frame garnish.

1. Install the front door glass run.

1. Engage the 2 claws and install a new front No. 1 door stiffener cushion with double-sided tape.

NOTICE:

The regulator arm must be below the intermediate position when installing the power window regulator motor.

1. Using a "TORX" driver (T25), install the front power window regulator motor sub-assembly with the 3 screws.

   Torque:

   5.4 N*m{55 kgf*cm, 48 in.*lbf}

   HINT:

   A new front window regulator adopts a self-tapping method. The installation position of the regulator will be threaded when the self-tapping screw is inserted.

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

2. Install the temporary bolt to the front door window regulator sub-assembly.

3. Temporarily install the window regulator.

4. Tighten the 6 bolts in the order shown in the illustration to install the front window regulator.

   Torque:

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

1. Insert the front door glass sub-assembly into the front door panel along the front door glass run as indicated in the order of the arrows in the illustration.

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

   Torque:

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

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. Install the new service hole cover.

   NOTICE:

   Securely install the front door service hole cover avoiding wrinkles and air bubbles.

4. Connect each connector and each clamp.

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

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

   Torque:

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

3. Connect the connector.

1. Install the front No. 1 speaker assembly with the 4 bolts.

2. Connect the connector.

1. Engage the 4 claws and install the front door inner glass weatherstrip.

1. Engage the 4 claws and install the front armrest base panel upper.

2. Install the 7 screws.

1. Install the front door wire with the 2 screws.

2. Engage the clamp.

1. Connect the connector.

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

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

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

1. Connect each connector.

2. Engage the front door trim board with the 4 clips of the front door inner glass weatherstrip.

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

4. Install the 3 screws and clip (A).

1. Connect the connector.

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

1. Engage the 6 claws and install the assist grip cover.

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

1. Engage the 2 clips and install the front door lower frame bracket garnish.