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Front Door: Removal

  1. Disconnect the ground cable from battery.
  2. Remove the front door trim. Refer to FRONT DOOR .
  3. Remove the outer mirror assembly. Refer to REMOVAL .
  4. Remove the front door speaker assembly.
    1. Remove the screws.
    2. Disconnect the harness connector and remove the front speaker assembly.
      Fig 1: Locating Front Speaker Assembly Screws
      G05663560Courtesy of SUBARU OF AMERICA, INC.
  5. Remove the front sealing cover.
    CAUTION:
    • Carefully remove the butyl tape. Excessive force will easily break the cover.
    • If the sealing cover gets broken, replace it with a new part.
    1. Remove the screw to remove the door trim bracket.
    2. Carefully remove the butyl tape to remove the sealing cover.
      Fig 2: Removing Sealing Cover
      G05004584Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the door sash and front door glass. Refer to REMOVAL .
  7. Remove the front door regulator and motor. Refer to REMOVAL .
  8. Remove the front door latch assembly. Refer to REMOVAL .
  9. Remove the front outer handle. Refer to REMOVAL .
  10. Remove the front door weather strip.
    CAUTION: If the weather strip clip is removed with excessive force, the weather strip may be damaged. Be sure to use clip remover to remove.
    Fig 3: Removing Front Door Weather Strip
    G05023074Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the bolts and nuts to remove the door checker.
    Fig 4: Locating Door Checker Bolts And Nuts
    G05958175Courtesy of SUBARU OF AMERICA, INC.
  12. Release the claws, and then remove the side sill cover-front INN.
    CAUTION: Do not pull with excessive force. Doing so may damage the claws of the side sill cover INN.
    Fig 5: Identifying Side Sill Cover - Front INN On Left And Right Sides Sections
    G06653171Courtesy of SUBARU OF AMERICA, INC.
    NOTE: To release the claws of the side sill cover INN, the following steps are recommended.
    1. Take out the weather strip from under the side sill cover INN.
    2. Turn over the floor mat and release the claw (C-C) by accessing from behind the side sill cover INN.
  13. Remove the clip, and remove the side sill cover front.
    Fig 6: Identifying Sill Cover Front Clip
    G06654088Courtesy of SUBARU OF AMERICA, INC.
  14. Disconnect the connector of door harness from body harness.
    Fig 7: Identifying Door Harness Connector
    G05023089Courtesy of SUBARU OF AMERICA, INC.
  15. Before removing the door panel, make the following preparations.
    Fig 8: Supporting Door Using Jack
    G05004578Courtesy of SUBARU OF AMERICA, INC.
    1. Put a wooden block on a floor jack and place the jack under the front door.
    2. Support the door with a jack to protect it from damage.
      CAUTION: Do not lift the door panel with a floor jack excessively. The door hinges may be damaged.
  16. Remove the door-side bolts for upper and lower hinges to remove front door panel.
    CAUTION: Door panels are heavy. When removing and installing them, always work in a team of two or more persons.
    Fig 9: Removing Door-Side Bolts
    G05004580Courtesy of SUBARU OF AMERICA, INC.
  17. Remove the door hinge from vehicle.
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