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Home >> Subaru >> 2019 >> BRZ Limited, Automatic Trans >> Repair and Diagnosis >> Body & Frame >> Exterior Body Panels >> Front Door >> Disassembly

Front Door: Disassembly

NOTE: The following procedure is for LH side. Unless otherwise specified, perform the same procedures for the LH and RH side.
  1. Disconnection of the battery ground terminal (Refer to REMOVAL )
  2. Removal of the door armrest cover LH
    1. Using a flat tip screwdriver that is wrapped in protective tape, release the 7 tabs.
    2. Release the guide, and remove the door armrest cover LH.
    G12595015Courtesy of SUBARU OF AMERICA, INC.
  3. Removal of the courtesy light ASSY (if there is a courtesy light) (Refer to REMOVAL )
  4. Removal of the front door trim board SUB-ASSY LH
    1. Using a flat tip screwdriver that is wrapped in protective tape, open the cap.
      G12595016Courtesy of SUBARU OF AMERICA, INC.
    2. Remove the clip.
    3. Remove the 3 screws.
      G12595017Courtesy of SUBARU OF AMERICA, INC.
    4. While pulling the front door trim board SUB-ASSY towards, release the 10 clips in the order shown in the figure.
    5. Disconnect each connector.
      G08555716Courtesy of SUBARU OF AMERICA, INC.
    6. Disconnect the front door lock remote control cable and the front door inside locking cable from the front door trim board SUB-ASSY LH.
      G12595019Courtesy of SUBARU OF AMERICA, INC.
  5. Removal of the front door inside handle SUB-ASSY LH
    1. Remove the 2 screws.
    2. Release the 2 guides, and remove the front door inside handle SUB-ASSY LH and the plate.
      G08555783Courtesy of SUBARU OF AMERICA, INC.
  6. Removal of the power window regulator master switch ASSY W/front armrest base panel UPR LH (driver side door)
    1. Remove the 4 screws.
    2. Release the tab, and remove the power window regulator master switch ASSY W/front door armrest base panel.
      G08555719Courtesy of SUBARU OF AMERICA, INC.
  7. Removal of the power window regulator master switch ASSY (driver side door) (Refer to REMOVAL )
  8. Removal of the power window regulator switch ASSY W/front armrest base panel UPR RH (passenger side door)
    1. Remove the 4 screws.
    2. Release the tab, and remove the power window regulator switch ASSY W/front door armrest base panel.
      G10217543Courtesy of SUBARU OF AMERICA, INC.
  9. Removal of the power window regulator switch ASSY (passenger side door) (Refer to REMOVAL )
  10. Removal of the outer mirror switch ASSY (Refer to REMOVAL )
  11. Removal of the door assist grip ASSY LH
    1. Remove the 2 screws.
    2. Release the guide, and remove the door assist grip ASSY LH.
      G12595023Courtesy of SUBARU OF AMERICA, INC.
  12. Removal of the front door trim pad LWR LH (2-speaker type)
    1. Remove the 5 screws, and remove the front door trim pad LWR LH.
      G08555722Courtesy of SUBARU OF AMERICA, INC.
  13. Removal of the front door trim pad LWR LH (6-speaker type)
    1. Remove the 5 screws, and remove the front door trim pad LWR LH.
      G12595025Courtesy of SUBARU OF AMERICA, INC.
  14. Removal of the front door speaker LH (6-speaker type)
    1. Remove the 2 screws, and remove the front door speaker LH.
    2. Remove the front door speaker grill LH from the front door speaker LH.
      G08555724Courtesy of SUBARU OF AMERICA, INC.
  15. Removal of the front door glass weather strip INN LH
    1. Set the 4 mm {0.1575 in} drill bit in the air drill.
    2. Wrap tape around the 4 mm {0.1575 in} drill bit about 5 mm {0.1969 in} behind the tip.
      NOTE: Wrapping the tape prevents grinding too deep.
    3. Lightly press the air drill against the rivet, grind the flange portion of the rivet, and remove the 6 rivets.
      CAUTION:
      • If you press the air drill too hard, the rivet will turn together, and will not be cut.
      • If you pry with the air drill while grinding, you may grind the hole where the rivet is installed or may damage the drill bit.
      • Be careful, because the cut rivet will be hot.
      G12595027Courtesy of SUBARU OF AMERICA, INC.
    4. Release the 9 tabs, and remove the front door glass weather strip INN LH.
      G08555726Courtesy of SUBARU OF AMERICA, INC.
  16. Removal of the speaker ASSY FR NO. 1 (if there is a speaker) (Refer to REMOVAL )
  17. Removal of the front door service hole cover LH
    1. Disconnect the connectors for the front door lock ASSY and the outer rear-view mirror ASSY.
    2. Remove the front door service hole cover LH.
      CAUTION: Remove any butyl tape left on the door panel.
      G08555727Courtesy of SUBARU OF AMERICA, INC.
  18. Removal of the outer rear-view mirror LH (Refer to REMOVAL )
  19. Removal of the front door glass weather strip ASSY OUT LH (Refer to REMOVAL )
  20. Removal of the front door glass SUB-ASSY LH
    1. Reconnect the battery ground terminal.
    2. Connect the power window regulator master switch ASSY connector and move the front door glass SUB-ASSY LH until you can see the front door glass SUB-ASSY LH mounting bolt.
    3. Disconnect the battery ground terminal.
    4. Disconnect the power window regulator master switch ASSY connector.
      G12595030Courtesy of SUBARU OF AMERICA, INC.
    5. Remove the 3 nuts, disconnect the front door frame SUB-ASSY RR LWR LH, and slide the front door frame SUB-ASSY RR LWR LH beyond the mounting section.
      G12595031Courtesy of SUBARU OF AMERICA, INC.
    6. Insert a flat tip screwdriver into the slit at the glass bolt tip. While holding it, remove the 2 nuts and disconnect the front glass SUB-ASSY LH.
    7. Loosen the front stabilizer mounting bolt.
      CAUTION: Be sure to hold the front glass SUB-ASSY LH and the front door frame SUB-ASSY RR LWR LH securely so that they don't fall.
      G12595032Courtesy of SUBARU OF AMERICA, INC.
    8. Remove the front door rear cover LH, and turn over the rear end of the front door weather strip so that the front glass SUB-ASSY LH can be removed.
      G08555731Courtesy of SUBARU OF AMERICA, INC.
    9. While lifting the front glass SUB-ASSY LH up, let the front door frame SUB-ASSY RR LWR LH slide down, and pull the front glass SUB-ASSY LH out from the front door frame SUB-ASSY RR LWR LH.
      CAUTION:
      • Be sure to hold the front glass SUB-ASSY LH and the front door frame SUB-ASSY RR LWR LH securely so that they don't fall.
      • Do not damage the front door glass.
      G12595034Courtesy of SUBARU OF AMERICA, INC.
    10. From the position shown in the figure, remove the front glass SUB-ASSY LH.
      CAUTION: Do not damage the front door weather strip.
      NOTE: The front glass SUB-ASSY LH cannot be removed from any position other than the one in the figure.
      G08555733Courtesy of SUBARU OF AMERICA, INC.
  21. Removal of the front door frame SUB-ASSY RR LWR LH.
    1. Remove the front door frame SUB-ASSY RR LWR LH from the front door frame.
  22. Removal of the door glass stabilizer INN
    1. Remove the bolt and remove the door glass stabilizer INN.
  23. Removal of the front door sash
    1. Remove the 3 nuts.
      G12595036Courtesy of SUBARU OF AMERICA, INC.
    2. In the order shown in the figure, turn the front door sash, and pull it out.
      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 glass, hold it securely.
      G12595037Courtesy of SUBARU OF AMERICA, INC.
  24. Removal of the front door sash stopper
    1. Remove the nut and remove the front door sash stopper.
  25. Removal of the front door window regulator W/motor ASSY
    1. Disconnect the connector.
    2. Loosen the tack bolt.
      CAUTION: If you remove the tack bolt, and the other 3 bolts and 2 nuts are removed, the front door window regulator W/motor ASSY may fall and be disfigured. Do not remove it.
    3. Remove the 3 bolts and the 2 nuts.
    4. Remove the tack bolt and remove the front door window regulator W/motor ASSY.
      G12595038Courtesy of SUBARU OF AMERICA, INC.
  26. Removal of the power window regulator motor ASSY LH (Refer to REMOVAL )
  27. Removal of the front door weather strip LH
    1. For the remaining front door weather strip LH, using a clip remover, release the 15 clips, and remove the front door weather strip LH.
      G08555737Courtesy of SUBARU OF AMERICA, INC.
  28. Removal of the front door outside handle cover W/lock cylinder ASSY (driver side door)
    1. Using a Torx socket wrench, remove the Torx screw, and remove the front door outer handle cover with lock cylinder ASSY LH.
      G12595040Courtesy of SUBARU OF AMERICA, INC.
  29. Removal of the front door outside handle cover FD (driver side door)
    1. Using a flat tip screwdriver, release the tab and the 2 guides, and remove the front door outer handle cover FD from the front door lock cylinder ASSY.
      G12595041Courtesy of SUBARU OF AMERICA, INC.
  30. Removal of the front door outside handle cover FP (passenger side door)
    1. Using a Torx socket wrench, remove the Torx screw, and remove the front door outside handle cover FP.
      G12595042Courtesy of SUBARU OF AMERICA, INC.
  31. Removal of the front door lock ASSY LH (Refer to REMOVAL )
  32. Removal of the front door outside handle ASSY LH
    1. Pull the front door outside handle ASSY LH towards the back of the vehicle, and release the front door outside handle frame SUB-ASSY LH.
    2. Pull the front door outside handle ASSY LH towards you, and remove it from the front door outside handle frame LH.
      G12595043Courtesy of SUBARU OF AMERICA, INC.
  33. Removal of the front door outside handle ASSY LH (if there is smart entry)
    1. Use the clip remover to release the clamp.
      G08555742Courtesy of SUBARU OF AMERICA, INC.
    2. Using a thin flat tip screwdriver that is wrapped in protective tape, release the 3 tabs and lift the connector cover.
    3. Disconnect the connector.
      G12595045Courtesy of SUBARU OF AMERICA, INC.
    4. Pull the front door outside handle ASSY LH towards the back of the vehicle, and release the front door outside handle frame SUB-ASSY LH.
    5. Pull the front door outside handle ASSY LH towards you, and remove it from the front door outside handle frame SUB-ASSY LH.
      G12595046Courtesy of SUBARU OF AMERICA, INC.
  34. Removal of the front door outside handle pad FR
    1. Release the 3 tabs and remove the front door outside handle pad FR.
      G12595047Courtesy of SUBARU OF AMERICA, INC.
  35. Removal of the front door outside handle pad RR
    1. Release the 2 tabs and remove the front door outside handle pad RR.
      G12595048Courtesy of SUBARU OF AMERICA, INC.
  36. Removal of the front door lock open rod LH
    1. In the order shown in the figure, release the front door outside handle snap, and remove the front door lock open rod LH.
      G12595049Courtesy of SUBARU OF AMERICA, INC.
  37. Removal of the front door outside handle frame SUB-ASSY LH
    1. Using a T30 Torx socket wrench, loosen the Torx screw.
    2. Pull towards the front of the vehicle, release the tab, and remove the front door outside handle frame LH.
      G12595050Courtesy of SUBARU OF AMERICA, INC.
  38. Removal of the front door check ASSY
    1. Remove the bolt and the 2 nuts and remove the front door check ASSY.
      G12595051Courtesy of SUBARU OF AMERICA, INC.
  39. Removal of the front door panel cushion
    1. Release the tabs and remove the 2 front door panel cushions.
      G12595052Courtesy of SUBARU OF AMERICA, INC.
  40. Removal of the side air bag sensor ASSY LH (Refer to REMOVAL )
  41. Removal of the front door hole cover
    1. Release the 4 tabs and remove the front door hole cover.
      G12595053Courtesy of SUBARU OF AMERICA, INC.
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