Exploded View

1. Front door panel
2. Grommet
3. Door hinge (upper)
4. Door hinge (lower)
5. Door check link
6. Bumper rubber
7. Door pad
8. Door striker
9. TORX bolt
10. Grommet

: Do not reuse
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Body grease

Door assembly

DOOR ASSEMBLY : Removal and Installation

CAUTION:
• Perform work with 2 workers, because of its heavy weight.

• When removing and installing front door assembly, support door with a jack and shop cloth to protect door and body.

REMOVAL

1. Disconnect front door harness connector.

2. Remove mounting bolt of door check link on the vehicle.

3. Remove door hinge mounting bolts (door side), and then remove door assembly.

INSTALLATION

Note the following items, and install in the reverse order of removal.

CAUTION:
• Apply anticorrosive agent onto the mounting surface.

• Check front door open/close, lock/unlock operation after installation.

• Check door hinge rotating part for poor lubrication. If necessary, apply body grease.

• After installation, perform the fitting adjustment. Refer to DLK-156, "DOOR ASSEMBLY : Adjustment".

• After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.

Door assembly : Adjustment

1. Front fender
2. Front door
3. Rear door
4. Body side outer
5. Door striker
6. TORX bolt
7. Front door hinge
8. Rear door hinge (upper) 9. Rear door hinge (lower)

: Do not reuse
: N·m (kg-m, ft-lb)
: Body grease

Check the clearance and surface height between front door and each part by visually and touching.

If the clearance and the surface height are out of specification, adjust them according to the procedures shown below.

FITTING ADJUSTMENT PROCEDURE

1. Remove front fender. Refer to DLK-152, "Removal and Installation".

2. Loosen door hinge mounting nuts on door side.

3. Adjust the surface height of front door according to the fitting standard dimension.

4. Temporarily tighten door hinge mounting nuts on door side.

5. Loosen door hinge mounting bolts on body side.

6. Raise front door at rear end to adjust clearance of the front door according to the fitting standard dimension.

7. After adjustment tighten bolts and nuts to the specified torque.

CAUTION:
• After installation, apply touch-up paint (the body color) onto the head of hinge mounting bolts and nuts.

• Check door hinge rotating part for poor lubrication. If necessary, apply body greas

e.

8. Install front fender. Refer to refer to DLK-152, "Removal and Installation".

DOOR STRIKER ADJUSTMENT

Adjust door striker so that it becomes parallel with door lock insertion direction.

Door striker

DOOR STRIKER : Removal and Installation

REMOVAL

Remove TORX bolts, and then remove door striker.

INSTALLATION

Note the following items, and install in the reverse order of removal.

CAUTION:
• Check front door open/close, lock/unlock operation after installation.

• After installation, be sure to perform the fitting adjustment. Refer to DLK-156, "DOOR ASSEMBLY : Adjustment".

Door hinge

DOOR HINGE : Removal and Installation

REMOVAL

CAUTION:
• Perform work with 2 workers, because of its heavy weight.

• When removing and installing front door assembly, support door with a jack and shop cloth to protect door and body.

1. Remove front fender. Refer to DLK-152, "Removal and Installation".

2. Remove front door assembly. Refer to DLK-154, "DOOR ASSEMBLY : Removal and Installation".

3. Remove front door hinge mounting bolts (body side), and then remove front door hinge.

INSTALLATION

Note the following items, and install in the reverse order of removal.

CAUTION:
• Apply anticorrosive agent onto the mounting surface.

• Check front door open/close, lock/unlock operation after installation.

• After installation, perform the fitting adjustment. Refer to DLK-156, "DOOR ASSEMBLY : Adjustment".

• After installation, apply touch-up paint (the body color) onto the head of door hinge mounting nuts.

• Check door hinge rotating part for poor lubrication. If necessary, apply body grease.

: Grease up point

Door check link

DOOR CHECK LINK : Removal and In

REMOVAL

1. Fully close the front door window.

2. Remove front door finisher. Refer to INT-13, "Removal and Installation".

3. Disconnect harness connector of front door speaker.

4. Remove mounting bolts of front door speaker, and then remove front door speaker.

5. Remove mounting bolt of door check link on the vehicle.

6. Remove mounting bolts of door check link on door panel.

7. Take door check link (1) out from the hole of door panel (2).

INSTALLATION

Note the following item, and install in the reverse order of removal.

CAUTION:
• Check front door open/close operation after installation.

• Check door check link rotating part for poor lubrication. If necessary, apply grease.

: Grease up point