Front Door Reassembly

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.
   

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.
   

   HINT:

   1. The most appropriate temperature for installing the tape is 25°C (77°F).
      
   2. When the temperature is low, the tape turns stiff and falls off easily. When the temperature is high, the tape loses elasticity.
      

Before installation

1. Remove any coating roughness 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.

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.

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 level of accuracy to achieve a neat finish and to avoid peeling.
   
2. 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° (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 (1.18 to 2.76 in.) 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 (0.394 to 0.787 in.) from the edge of the squeegee.
      

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

1. 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 tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

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.
   

Check after installation

1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply new tape.
   

   NOTICE:

   Do not reuse the tape.

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

Engage the 16 clips and install the front door weatherstrip.

Install the front door check assembly with the 3 bolts.

Torque:

Bolt (1):

30 N*m{306 kgf*cm, 22 ft.*lbf}

Bolt (2):

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

Install the door electrical key oscillator with the screw.

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

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

Engage the claw and grommet.

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}

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

Engage the claw (A) and grommet.

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}

Engage the claw (B).

Connect the connector.

Install the front door inside locking cable assembly.

Install the front door inside locking cable assembly.

Engage the 3 claws.

Install the front door lock remote control cable assembly.

Install the front door lock remote control cable assembly.

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

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

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

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}

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

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

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

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

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}

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

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

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

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

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

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

Connect the connector.

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

Install the front door lock cylinder.

HINT:

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

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}

Install the hole plug.

w/o Wireless door lock system:

HINT:

Use the same procedure for the front passenger side and the driver side.

w/ Wireless door lock system:

1. 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}

2. Install the hole plug.
   

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

Torque:

6.2 N*m{63 kgf*cm, 55 in.*lbf}

Install a new door frame garnish with the clip.

Install the front door glass run.

Insert the 2 guides and install the front door No. 2 stiffener cushion with the 2 bolts.

Torque:

6.2 N*m{63 kgf*cm, 55 in.*lbf}

Using a "TORX" socket wrench (T25), install the front power window regulator motor assembly with the 3 screws.

Torque:

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

HINT:

A new front window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

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

Install the front door window regulator assembly with the 5 bolts.

Torque:

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

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

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

Temporarily install the front door window regulator sub-assembly.

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

Torque:

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

Connect the connector.

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

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

Torque:

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

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

Install the 3 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Engage the clamp and connect the connector.

Apply butyl tape to the front door panel.

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

Attach the front door service hole cover according to the reference points on the front door panel.

NOTICE:

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

w/ Power door lock:

1. Connect the connector.
   

Check that the ignition switch is off.

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

CAUTION:

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

Before connecting the connector, check that the position of the white housing lock is correct as shown in the illustration.

Insert the pin (stopper) into the door hole and install the door side airbag sensor to the front door panel with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

NOTICE:

1. If the door side airbag sensor has been dropped, or there are any cracks, dents or other defects in the case or connector, replace it with a new one.
   
2. When installing the door side airbag sensor, be careful that the SRS wiring does not interfere with or is not pinched between other parts.
   
3. Make sure that the pin (stopper) is securely inserted into the door hole.
   
4. Tighten the bolt while holding the door side airbag sensor because the door side airbag sensor pin (stopper) is easily damaged.
   

Connect the connector to the door side airbag sensor.

NOTICE:

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

1. Be sure to engage the connectors until they are locked (when locking, make sure that a click sound can be heard).
   
   

   
   
   
   
   

   Text in Illustration

   *1	White Housing Lock	*2	Yellow CPA
   *a	Connection is Completed	-	-

   HINT:

   When engaged, the white housing lock will slide. Be sure not to hold the white housing lock or part (A), as it may result in an insecure fit.

Check that there is no looseness in the installed parts of the door side airbag sensor.

Install the front door trim bracket with the 2 screws.

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

NOTICE:

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

HINT:

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

Connect the connector.

Install the front door inner glass weatherstrip.

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

Engage the clip and clamp, and install the front door lower frame bracket garnish.

Connect the connector.

Engage the clip and clamp, and install the front door lower frame bracket garnish.

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

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

Engage the front door trim board with the 5 claws on the front door inner glass weatherstrip.

Engage the 10 clips and install the front door trim board to the front door panel.

Install the 2 screws.

Engage the claw to install the door armrest cap.

Engage the 2 claws and install the door control switch assembly.

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

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

Engage the 2 clips and 6 claws, and install the front armrest upper base panel.

w/ Power Door Lock:

1. Connect the connector.
   

Connect the connector.

Engage the 2 clips and 6 claws, and install the front armrest upper base panel.

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

Temporarily install the front door window regulator handle assembly and fully close the window glass.

Install the front door regulator inside handle plate.

Install the snap ring to the front door window regulator handle assembly.

Install the front door window regulator handle assembly as shown in the illustration.