Hyundai Tucson: Exterior / Front Door Repair procedures

Replacement
Front Door Trim Replacement
   
When prying with a flat-tipped screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
Put on gloves to protect your hands.
1.
Using a screwdriver or remover, remove the quadrant inner cover (A).
2.
Disconnect the tweeter speaker connector (B).

3.
After loosening the mounting screws, then remove the door inside handle housing (B).
4.
After loosening the mounting screws, then remove the door trim (A).

5.
Push the lock pin (A), disconnect the connectors (B).

6.
Install in the reverse order of removal.
   
Make sure connectors are connected properly and each rod is connected securely.
Make sure the door locks/unlocks and opens/closes properly.
Replace and damaged clips.
Inside Handle Replacement
1.
Remove the door trim.
2.
Remove the door screen (A).
   
Replace ant damaged screen.

3.
After loosening the mounting screws, then remove the inside handle (A).

4.
Disconnect the inside handle cable (B).

5.
Install in the reverse order of removal.
   
Make sure the door locks/unlocks and opens/closes properly.
Replace ant damaged clips.
Glass Replacement
1.
Remove the front door trim.
2.
Remove the door screen.
3.
Remove the glass mounting plug hole.
   
Take care not to drop to glass and scratch the glass surface.
4.
Carefully adjust the glass (B) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.

Tightening torque :
6.9 ~ 10.8 N.m (0.7 ~ 1.1kgf.m 5.1 ~ 8.0 lb-ft )

5.
Install in the reverse order of removal.
   
Roll the glass up and down to see if it move freely without binding.
Adjust glass position as needed.
Replace ant damaged clips.
Make sure the door locks/unlocks and opens/closes properly.
Speaker Replacement
1.
Remove the door trim.
2.
Remove the door screen.
3.
After loosening the mounting screws, remove the speaker (B).
4.
Disconnect the speaker connector (A).

5.
Install in the reverse order of removal.
   
Use sheet metal screws to secure the speaker.
Replace ant damaged clips.
Make sure the door locks/unlocks and opens/closes properly.
Make sure connectors are connected properly and each rod is connected securely.
Power Window Motor Replacement
1.
Remove the door trim.
2.
Remove the door screen.
3.
Disconnect the connector (A), then loosen the mounting screws.
4.
Remove the power window motor (B).

5.
Install in the reverse order of removal.
   
Grease should be applied to areas where there is rotational parts and springs.
Roll the glass up and down to see if it move freely without binding.
Replace ant damaged clips.
Make sure the door locks/unlocks and opens/closes properly.
Door Module Assembly Replacement
1.
Remove the following parts :
A.
Front door trim
B.
Door screen.
C.
Window glass
D.
Outside handle
2.
Loosen the outside handle base mounting screw (A).

3.
Disconnect the outside handle connector (A).

4.
Loosen the module mounting bolts.
5.
Loosen the latch mounting nuts, remove the module (A).

Tightening torque :
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft )

6.
Disconnect the connector (A) and clip.

7.
Install in the reverse order of removal.
   
The area of whole parts should be applied with sufficient grease.
Make sure connectors are connected properly and each rod is connected securely.
Make sure the door locks/unlocks and opens/closes properly.
Replace ant damaged clips.
Outside Handle Replacement
1.
Remove the cap, loosen the mounting bolt.
2.
Remove the outside handle cover (A).

Tightening torque :
6.9 ~ 10.8 N.m (0.7 ~ 1.1kgf.m 5.1 ~ 8.0 lb-ft )

3.
Remove the outside handle (A), by sliding it rearward.

4.
Disconnect the outside handle connector (A).

5.
Install in the reverse order the removal.
   
Make sure the door locks/unlocks and opens/closes properly.
Adjustment
Glass Adjustment
   
Check the glass run channel for damage or deterioration, and replace them necessary.
1.
Remove the door trim.
2.
Remove the door screen.
3.
Carefully move the glass (A) until the glass mounting bolt are visible, then loosen them.

4.
Check that the glass moves smoothly.
Door Striker Adjustment
Make sure the door latches securely without slamming it. If necessary adjust the striker (A) : The striker nuts are fixed. The striker can be fine adjusted up or down, and in or out.
1.
Loosen the screws (B) just enough for the striker to move.

Tightening torque (B):
8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft )

2.
Tap on the striker with a plastic hammer to adjust the striker. The striker will not move much, but will give some adjustment.
3.
Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck.
Door Position Adjustment
   
After installing the door, check for a flush fit with the body, then check for equal gaps between the front, rear, and bottom, door edges and the body. Check that the door and body edges are parallel. Before adjusting, replace the mounting bolts.
1.
Place the vehicle on a firm, level surface when adjusting the doors.
2.
Check that the door and body edges are parallel.

3.
Adjust at the hinges (A) :
A.
Loosen the door mounting bolts slightly, and move the door IN or OUT until it aligns flush with the body.
B.
Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize the gaps.
C.
Place a shop towel on the jack to prevent damage to the door when adjusting the door.

Tightening torque :
(B) : 34.3 ~ 41.2 N.m (3.4 ~ 4.2 kgf.m, 25.3 ~ 30.4 lb-ft 7)
(C) : 9.8 ~ 19.6 N.m (1.0 ~ 2.0 kgf.m, 7.2 ~ 14.5 lb-ft )

4.
Grease the pivot portions of the hinges indicated.
5.
Check for water leaks.
Front Door Components and Components Location
Components 1.Door inside handle housing2. Door trim3. Door belt inner weatherstrip 4. Door screen 5. Door module 6. Quadrant inner cover 7. Door panel 8. Door belt outside weatherstrip9. Door si ...

Rear Door Components and Components Location
Components 1. Door inside handle housing 2. Door trim3. Door belt inner weatherstrip4. Door screen5. Door module6. Door panel7. Door delta inner cover8. Door belt outside weatherstrip9. Door delt ...

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