Repair Procedures
Replacements
Front Door Trim Replacement
CAUTION:
- Take care not to scratch the door trim and other parts.
- Put on gloves to protect your hands.
1. Using a screwdriver or remover, remove the front door quadrant inner cover (A).
2. Remove the front door inside handle cover (A) and front door trim pad (B).
3. After loosening the mounting screws, then remove the front door trim (A).
4. Disconnect the front door inside handle cage (A).
5. Disconnect the twitter speaker connector (A), outside rear view mirror switch connector (B), power window switch connector (C).
6. Installation is the reverse of removal.
NOTE:
- Make sure of connectors is plugged in properly and each rod is connected securely.
- Make sure the door locks/unlocks and opens/closes properly.
- Replace any damaged clips.
Inside Handle Replacement
1. Remove the front door trim.
2. After loosening the mounting screws, then remove the front door inside handle (A).
3. Installation is the reverse of removal.
NOTE:
- Replace any damaged clips.
- Make sure the door locks/unlocks and opens/closes properly.
Glass Replacement
1. Remove the front door trim.
2. Remove the glass mounting hole plug.
NOTE:
- Use the door switch to align the mounting hole/bolt with the hole in the door.
- If unable to operate the window motor, remove the motor and align the hole by hand.
- Be careful not to drop the glass and/or scratch the glass surface.
3. Carefully move the glass (B) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.
Tightening torque :
3.9 - 2.9 N.m (0.4 - 1.2 kgf.m, 11.8 - 8.7 lb-ft)
4. Installation is the reverse of removal.
NOTE:
- Roll the glass up and down to see if it moves freely without binding.
- Adjust glass position as needed.
- Make sure the door locks/unlocks and opens/closes properly.
- Replace any damaged clips.
Speaker Replacement
1. Remove the front door trim.
2. Disconnect the speaker connector (A).
3. Drill out the rivets to remove the speaker (B).
4. Installation is the reverse of removal.
NOTE:
- Use sheet metal screws to secure the speaker.
- Make sure connectors are connected properly and each rod is connected securely.
- Make sure the door locks/unlocks and opens/closes properly.
- Replace any damaged clips.
Power Window Motor Replacement
1. Remove the front door trim.
2. Disconnect the power window motor connector (A).
3. After loosening the mounting screws, then remove the power window motor (B).
4. Installation is the reverse of removal.
NOTE:
- The area of rotational parts and springs should be applied with sufficient grease.
- Roll the glass up down to see if it move freely without binding.
- Make sure the door locks/unlocks and opens/closes properly.
- Replace any damaged clips.
Door Module Replacement
1. Remove the front door trim.
2. Remove the front door window glass.
3. Loosen the door latch mounting screws.
4. After loosening the mounting bolts, then remove the front door module (A).
Tightening torque :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)
5. Disconnect the front door module wiring harness.
6. Remove the front door module (A).
7. Installation is the reverse of removal.
NOTE:
- The area of whole parts should be applied with sufficient grease.
- Make sure the connector is plugged in properly and each rod is connected securely.
- Make sure the door locks/unlocks and opens/closes properly.
- Replace any damaged clips.
Outside Handle Replacement
1. Remove the front door trim.
2. After loosening the mounting bolt, then remove the outside handle cover (A).
Tightening torque :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)
3. Remove the outside handle (A) by sliding it rearward.
4. Disconnect the outside handle connector (A).
5. Remove the outside handle bushing (A).
6. Installation is the reverse the removal.
NOTE:
- Make sure the door locks/unlocks and opens/closes properly.
- Make sure the connector is plugged in properly and each rod is connected securely.
Door Latch Replacement
1. Remove the front door trim.
2. Remove the front door window glass.
3. Remove the front door module.
4. Remove the outside handle.
5. Loosen the mounting screw (A).
6. After loosening the mounting screws, then remove the front door latch (A).
Tightening torque :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)
7. Disconnect the front door latch connector (A).
8. Installation is the reverse of removal.
NOTE:
- Make sure the door locks/unlocks and opens/closes properly.
- Make sure the connector is plugged in properly and each rod is connected securely.
Door Channel Replacement
1. Remove the front door trim.
2. Remove the front door window glass.
3. Remove the front door module.
4. After loosening the mounting nuts, then remove the door channel (A).
Tightening torque :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)
5. Installation is the reverse of removal.
Adjustment
Glass Adjustment
NOTE:
- Check the glass run channel for damage or deterioration, and replace them as needed.
1. Remove the front door trim.
2. Remove the glass mounting hole plug.
3. Carefully move the glass (A) until the glass mounting bolts are visible, then loosen them.
4. Check that the glass moves smoothly.
5. Raise the glass fully, and check for gaps. Check that the glass contacts the glass run channel evenly.
6. Check for water leaks. Run water over the roof and on the sealing area as shown, and note these items:
A. Use a 12mm (1/2in.) diameter hose (A).
B. Adjust the rate of water flow as shown (B).
C. Do not use a nozzle.
D. Hold the hose about 300mm(12in.) away from the door.
Door Striker Adjustment
Make sure the door latches securely without slamming it. If necessary adjust the striker (A): The striker nuts are fixed. The striker can be adjusted up or down, and in or out.
1. Loosen the screws (B) just enough for the striker to move.
Tightening torque :
(B): 16.7 - 21.6 N.m (1.7 - 2.2 kgf.m, 12.3 - 15.9 lb-ft)
2. Tap on the striker with a plastic hammer to adjust the striker. The striker will not move much, but will give some adjustment.
3. Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck.
Door Position Adjustment
NOTE:
- After installing the door, check for a flush fit with the Body, then check for equal gaps between the front, rear, and bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the mounting bolts.
1. Check that the door and body edges are parallel.
2. Place the vehicle on a firm, level surface when adjusting the doors.
3. Adjust at the hinges (A) :
A. Loosen the door mounting bolts slightly, and move the door in or out until it aligns flush with the body.
B. Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize the gaps.
C. Place a shop towel on the jack to prevent damage to the door when adjusting the door.
Tightening torque :
(B): 21.6 - 26.5 N.m (2.2 - 2.7 kgf.m, 15.9 - 19.5 lb-ft)
(C): 33.3 - 41.2 N.m (3.4 - 4.2 kgf.m, 24.6 - 30.4 lb-ft)
4. Grease the pivot portions of the hinges indicated.
5. Check for water leaks.