Page 993 of 2248
B5M0068
8. OUTER HANDLE
1) Remove trim panel.
2) Remove sealing cover.
3) Detach door latch rod from outer handle and key lock.
4) Loosen nut securing outer handle and then remove
outer handle from outside.
CAUTION:
Be careful not to damage door.
Installation is in the reverse order of removal.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
B5M0069A
9. KEY LOCK
1) Remove trim panel.
2) Remove sealing cover.
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring
1securing key lock.
6) Remove key lock from outer handle.
Installation is in the reverse order of removal.
NOTE:
Install so that key slot in key lock comes to center of hole
in outer handle.
B5M0070A
10. GUSSET
NOTE:
Be sure window is all the way down.
1) Remove trim panel.
2) Remove door rearview mirror.
3) Remove sealing cover.
4) Remove bolts and nuts which secure gusset.
5) Lift out gusset
1.
To install, reverse the above removal procedures.
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5-2SERVICE PROCEDURE
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Page 994 of 2248
B: ADJUSTMENT
1. DOOR ASSY
1) Using ST, loosen bolts securing upper and lower hinges
to body, and adjust fore-and-aft and vertical alignment of
door.
ST 925610000 DOOR HINGE WRENCH
B5M0071A
2) Loosen mounting screws approximately one rotation.
Adjust striker
1position by lightly tapping with hammer. (To
adjust, utilize the shape of striker nut plate
2support.)
CAUTION:
Use cloth to prevent damaging body or other parts.
Do not directly tap striker plastic portion.
Do not apply impact on spot-welded striker nut
plate.
Hinge tightening torque (body side):
29±5 N⋅m (3.0±0.5 kg-m, 21.7±3.6 ft-lb)
Striker tightening torque:
14±4 N⋅m (1.4±0.4 kg-m, 10.1±2.9 ft-lb)
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Page 995 of 2248
2. PROCEDURE CHART FOR ADJUSTING DOOR
GLASS
Insert door glass.
Mount door glass on regulator.
Install front and rear upper stoppers.
Install inner stabilizer.
Align upper stopper position.
Align adjusting bolt with nut.
Remedy for unequal dimensions
Remedy for improper window glass-to-center
pillar clearance
Remedy for improper window glass-
to-weatherstrip contact
Not O.K. Not O.K. Not O.K.
Close the door and check all clearances are as specified.
O.K.
END
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Page 996 of 2248
3. FRONT DOOR GLASS
B5M0072A
G5M0421
Door glass fit adjustment
Before adjusting door glass alignment, ensure adjusting
bolts for stabilizers, upper stoppers and sashes are loose
and glass is raised so that it is in contact with upper and
side weatherstrip.
1) Temporarily tighten one of the two rear sash adjusting
bolts, at midpoint of oblong hole on inner panel.
2) Temporarily tighten B channel regulator at a position
slightly lower than midpoint of oblong hole on inner panel.
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5-2SERVICE PROCEDURE
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Page 997 of 2248
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in) from
fully closed position. While applying outward pressure
(load) to upper edge of glass above midpoint of two outer
stabilizers, press inner stabilizer until it just touches the
glass, then secure it.
Load: F
Front door glass 39 N (4 kg, 9 lb)
Rear door glass 34.3 N (3.5 kg, 7.7 lb)
G5M0498
Remedy for unequal dimensions, between upper,
lower and center pillar sides
1) Close front door and raise door glass.
2) Make sure of unequal dimensions.
B5M0073A
3) If glass tilts to far rearward, loosen adjusting nutCand
adjust glass to be parallel with center pillar, then after
adjustment, tighten adjusting nut
C.
B5M0074A
Remedy for improper glass to center pillar clearance
1) Close front door and raise door glass.
2) Make sure of improper clearance.
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5-2SERVICE PROCEDURE
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Page 998 of 2248

B5M0075A
3) If clearance is improper, loosen adjusting nutA, boltA
and adjust glass to center pillar.
G5M0511
Remedy for improper upper stop point of door glass
1) Loosen front and rear sash stoppers.
2) Increase the upward travel of window glass up to the
position where upper edge just touches weatherstrip sur-
face with door closed.
3) After adjustment, temporarily tighten stoppers.
NOTE:
Make sure that each glass stopper is touched.
B5M0076A
Remedy for incorrect contact of door glass to weath-
erstrip
1) Close front door and raise door glass.
2) If clearance is below specifications, loosen bolt
Aand
bolt
B.
3) If clearance is over specifications, tighten bolt
Aand
bolt
B.
B5M0076A
Fit adjustment
Door glass fit is adjusted by displacing the glass front edge
with a stabilizer.
NOTE:
Before adjusting glass fit, visually check to determine rela-
tive adjusting positions of retainer and molding (on roof
side) and glass surface.
1) Alternately adjust two rear sash adjusting bolts
Auntil
dimensions (indicated in figure) are obtained.
CAUTION:
Do not loosen two adjusting nuts
Aat the same time,
as this moves sash fore and aft, creating unequal
glass-to-sash clearance. During adjustment, loosen
only one nut and keep the other tightened.
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5-2SERVICE PROCEDURE
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Page 999 of 2248
B5M0077A
NOTE:
Always adjust two rear sash adjusting bolts
Aby the same
amount. Do not adjust the adjusting bolts with sash bracket
inclined toward inner panel, as this increases effort
required to operate regulator.
2) Adjust front sash fit using rear sash adjustment proce-
dure outlined above as a guide. Two adjusting bolts must
be adjusted by the same amount.
NOTE:
Front and rear sash adjustment procedures are basically
the same; however, the amount of adjustment is not always
the same due to alignment dispersion of individual doors.
Adjust front and rear sash fit, as equally as possible.
Otherwise, effort required to operate regulator may
increase.
3) After adjusting front sash-to-glass fit, secure front sash.
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5-2SERVICE PROCEDURE
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Page 1000 of 2248
4. REAR DOOR GLASS
Alignment of rear door glass is basically the same as for
the front door glass. Due to slight difference in adjustment
dimensions for fore-aft, up-down, and in-out alignments,
key points for rear door adjustment are described below.
B5M0078A
B5M0074A
Fore-aft adjustment
1) Door glass alignment must be adjusted so that glass-
to-center pillar fit is equal at all points. Always use dimen-
sions (indicated in figure) as a guide during adjustment.
NOTE:
If dimensions are smaller than those indicated, glass will be
caught in weatherstrip and may not raise to the fully closed
position.
2) After making fore-aft adjustment, raise and lower glass
to ensure it is free from any binding.
25
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