Front Door: Assembly

1. Apply body grease to the sliding parts of the front door window regulator, the front door check ASSY LH, the front door outside handle frame SUB-ASSY LH, and the front door lock ASSY LH.

1. Fit in the 4 tabs and install the front door hole cover.

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1. Fit in the 2 tabs and install the 2 front door panel cushions.

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1. Using 2 nuts, install the front door check ASSY.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

2. Install the bolt.

   Standard value: T=33N.m {336kgf.cm} {24.3ft.lbf}

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1. Pull towards the back of the vehicle, fit in the tab, and temporarily install the front door outside handle frame SUB-ASSY LH on the front door panel.
2. Using a Torx socket wrench and a Torx screw, install the front door outer handle frame SUB-ASSY LH.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

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1. In the order shown in the figure, fit in the front door outside handle snap, and attach the front door lock open rod LH to the front door outside handle frame LH.

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1. Fit in the 3 tabs and install the front door outside handle pad FR.

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1. Fit in the 2 tabs and install the front door outside handle pad RR.

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1. Insert the front end of the front door outside handle ASSY LH into the front door outside handle frame SUB-ASSY LH.
2. Insert the rear end of the front door outside handle ASSY LH into the front door outside handle frame SUB-ASSY LH, and install it by sliding it towards the front of the vehicle.

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3. Connect the connector.
4. Fit in the 3 claws.

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5. Fit in the clamp.

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1. Insert the front end of the front door outside handle ASSY LH into the front door outside handle frame SUB-ASSY LH.

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1. Fit in the tab and the 2 guides, and install the front door outside handle cover FD on the front door lock cylinder ASSY.

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1. Assemble the front door outside handle cover W/lock cylinder ASSY.
   NOTE: Check that the front door lock cylinder rod is inserted into the front door lock ASSY LH.

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2. Using a Torx socket wrench and a Torx screw, install the front door outside handle cover W/lock cylinder ASSY.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

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1. Using a Torx socket wrench and a Torx screw, install the front door outside handle cover FP.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

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1. Fit in the 15 clips.
2. Install the 3 rear sections after installing the front door glass weather strip ASSY OUT LH.

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1. With the tack bolt, temporarily install the front door window regulator W/motor ASSY on the front door panel.
2. With 3 bolts and 2 nuts, install the front door window regulator W/motor ASSY.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

3. Completely tighten the tack bolt.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

4. Connect the connector.

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1. Install the front door sash stopper with a bolt.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

1. As in the figure, insert the front door sash into the front door frame at a right angle.
   CAUTION:

   • The mounting bolt of the front door sash will interfere, so be sure to perform this task in the order in the figure.
   • To avoid damaging the front door sash, hold it securely.
2. Turn the front door sash 90°.

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3. Using 3 nuts, install the front door sash.

   Standard value: Nut (A)

   T=14N.m {143kgf.cm} {10.3ft.lbf}

   Standard value: Nut (B)

   T=7.5N.m {77kgf.cm} {5.5ft.lbf}

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1. Using 3 nuts, install the front door frame SUB-ASSY RR LWR LH.

   Standard value: T=14N.m {143kgf.cm} {10.3ft.lbf}

1. Reconnect the battery ground terminal.
2. Connect the power window regulator master switch ASSY connector and move the front door window regulator until you can see where the front door glass SUB-ASSY LH is installed.
3. Disconnect the battery ground terminal.
4. Disconnect the power window regulator master switch ASSY connector.
5. From the position shown in the figure, insert the front door glass SUB-ASSY LH into the front door frame.
   CAUTION: Do not damage the front door weather strip LH.
   NOTE: Because the front door glass SUB-ASSY LH cannot be installed in a position other than the one in the figure, perform this task while sliding the front door frame SUB-ASSY RR LWR LH.

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6. Set the grommet part of the front door glass SUB-ASSY LH into the rail of the front door frame SUB-ASSY RR LWR LH.
   CAUTION:

   • To avoid dropping the front door glass SUB-ASSY LH and the front door frame SUB-ASSY RR LWR LH, hold them securely.
   • Do not damage the front door glass.
7. Using 2 nuts, install the front door glass SUB-ASSY LH.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

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1. Install the door glass stabilizer INN with a bolt.

   Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}

1. Inspect the front door glass installation. (Refer to ADJUSTMENT )
2. Adjust the placement of the front door glass. (Refer to TRUNK PANEL )

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1. Apply new butyl tape to the door panel.
   CAUTION:

   • The butyl tape must overlay for 20 cm {7.874 in} or more.
   • The butyl tape must not block the water draining holes in the front door panel.
2. Put the front door lock remote control cable LH, the rear door inside locking cable LH and every connector through the new front door service hole cover LH.
3. Align the new front door service hole cover LH with the front door panel standard position, and apply.
   CAUTION: To avoid wrinkles and bubbles, push with enough force when applying the front door service hole cover LH.
4. Connect each connector.

1. As in the figure, fit in the 9 tabs and install the new front door glass weather strip INN LH on the front door trim board SUB-ASSY LH.
2. Fit in the tab.

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3. Attach nosepiece No. 1 to the air riveter (a product that supports 93.2 mm {0.13 in}), and insert the mandrel of the new rivet into the nosepiece.
4. Once the rivets have been vertically pushed into the installation holes, use the air riveter to install the 6 rivets.
5. If you can't cut the shaft, pull again to cut off the shaft, removing the head as well.

   Preparation tool & preparation items: Air riveter (product that supports 93.2 mm {0.13 in})

   Rivet

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6. After installing the rivet, cut non-woven tape into a 15 mmx15 mm {0.59 in x0.59 in} square and apply to the crimped section.
   CAUTION: The crimped section of the rivet should be 3 mm {0.12 in} high. It may interfere with the door panel. If the crimping is insufficient, push it down with pliers.

   Preparation items: Non-woven tape: 94029FG000

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7. After installing the weather strip INN, perform the following inspections.
   • There is no gap between the weather strip INN LH and the front door trim board SUB-ASSY LH.
   • There is no looseness when you lightly pull on the weather strip INN LH.

1. Using 5 screws, install the front door trim pad LWR LH.

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1. Install the front door speaker grill LH on the front door speaker LH.
2. Using 2 screws, install the front door speaker LH.

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1. Using 5 screws, install the front door trim pad LWR LH.

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1. Fit in the guide, and with 2 screws, install the door assist grip ASSY LH.

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1. Fit in the tab, and using 4 screws, install the power window regulator master switch ASSY W/front armrest base panel UPR LH on the front door trim board SUB-ASSY LH.

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1. Fit in the tab, and using 4 screws, install the power window regulator switch ASSY W/front armrest base panel UPR RH on the front door trim board SUB-ASSY RH.

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1. Fit in the 2 guides.
2. Using 2 screws, install the front door inside handle SUB-ASSY LH with the plate on the front door trim board SUB-ASSY LH.

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1. Connect the front door lock remote control cable LH and the front door inside locking cable LH to the door remote ASSY LH.

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2. Connect each connector.
3. Insert the upper side of the front door trim board SUB-ASSY LH first.
4. Fit in the 10 clips and install the front door trim board SUB-ASSY LH on the front door panel.
   CAUTION: When installing the front door panel, do not hit the shaded area.

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5. Install the 3 screws and a clip.

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6. Fit in the tab and install the cap.

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1. Fit in the 7 tabs and the guide, and install the door armrest cover LH.

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Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}