05/08/2024 02:38:01

Handle - Exterior Release - Door - Front - LH - Generation 2.1 (Retrofit)

Correction Code 11451016

  • 2024-04-09: Procedure updated to latest validation.
  • 2023-08-30: Revised title for the hyperlink for the recalibration procedure.

Special tool(s) required for this procedure:

Part Number Description
1103741-10-A Window switch tool (front)
1080985-10-A Door handle alignment kit
1054712-00-A Thread setter kit (NA, APAC)
1118491-00-A SEALED CONNECTOR PLUG, LED (base door handles)

Generation 2.0 Handle Assembly Removal

  1. Enable Service Mode through the touchscreen. See Service Mode.
  2. Shift into Neutral, press the brake pedal, and then touch the Park Brake icon on the touchscreen.
  3. Remove the LH front door trim panel. See Panel - Door Trim - Front - LH (Remove and Install).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If present, do not detach the retention strap. Support the trim panel to prevent damaging the retention strap or the trim panel tether rivet.
  4. Use a pen or similar object to latch the front door.
    Informational PurposesAn informational icon, calling your attention
    Note
    The latch mechanism is closed after 2 clicks.
  5. Connect the window switch tool to the LH door harness, and then fully raise the window.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Do not close the door with the window in fully raised position.
  6. Apply masking tape on the outside of the vehicle to mark the position of the window glass relative to the bright work, and then carefully cut the tape from both sides of the bright work.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Be careful not to scratch the vehicle paint.
  7. Make sure the door handle is retracted.
  8. Apply masking tape on the outside of the vehicle to cover the door handle grip.
  9. Carefully ease the flap seal clear of the inner belt seal for access.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage component(s).
  10. Carefully lift and remove the inner belt seal.
  11. Remove the LH front door outer belt seal. See Seal - Outer Belt - Front Door - LH (Remove and Replace).
  12. Remove the adhesive patches from the inner door access openings.
  13. Loosen, but do not remove, the fastener securing the door glass to the regulator (torque 7.5 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Take care not to damage component(s).
  14. Remove the LH front door glass.
    Informational PurposesAn informational icon, calling your attention
    Note
    1x locking tab. Lower the LH front window to access the window locking tab, push and release the tab to remove the glass.
  15. Use the window switch tool to fully lower the LH front window regulator.
  16. Remove the fasteners (x3) that attach the door controller to the closeout panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    It is not necessary to disconnect the electrical connectors from the door controller.
  17. Tie the door controller aside.
  18. Remove the fasteners (x6) that attach the closeout panel to the door (torque 4 Nm).
  19. Remove and discard the closeout panel.
    Informational PurposesAn informational icon, calling your attention
    Note
    In the following steps, remove any plugs or waterproof tape that covers any of the fasteners.
  20. Release the door handle harness connector clip and disconnect the door handle harness connector.
  21. Remove the nuts (x4) that attach the door handle assembly to the door outer panel.
  22. Carefully remove the door handle assembly from the vehicle.
  23. Remove and discard the door handle assembly back seal.
    Informational PurposesAn informational icon, calling your attention
    Note
    It may be necessary to rip off the back seal as it is attached by 4 push nuts that cannot be re-used once installed.
  24. Remove the screws (x4) that attach the back plate to the handle grip, and then remove the back plate from the assembly.
  25. Remove the door handle grip from the door handle assembly and set it aside.
    Informational PurposesAn informational icon, calling your attention
    Note
    The door handle grip on 2.0 door handles is made of metal and has slightly larger openings for the door handle cartridges compared to the 2.xx and 3.0 door handle grips which are made of plastic. The door handle grip must be transferred to maintain consistency with the rest of the door handles installed on the vehicle if equipped with 2.0 door handles. The updated service replacement handle will have slightly smaller grip cartridges and the use of adhesive and spacers is therefore required to maintain a snug fit of the metal door handle grip.

Generation 2.1 Handle Assembly Retrofit

Warning IconA warning icon, calling your attention to a possibly risky situation
Warning
Always replace plugs or tape removed from the front door shells when servicing or inspecting the door or its components. Additional holes in the door creates more escape paths for air, which decreases the front door pressure sensor's ability detect a side impact, and can negatively affect airbag deployment.
  1. Install spacers on the handle fork.
    1. Remove the tape covering the adhesive on the spacer for the front-most fork arm.
    2. Place the spacer, with the adhesive side down, on the front-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    3. Remove the tape covering the adhesive on the spacer for the rear-most fork arm.
    4. Place the spacer, with the adhesive side down, on the rear-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    5. Remove the tape covering the adhesive on the second spacer for the rear-most fork arm.
    6. Place the spacer, with the adhesive side down, in the center of the small flat area above the hole on the rearmost fork arm.
  2. Install the door handle grip to the door handle assembly.
  3. Install the LED light assembly to the door grip.
  4. Install the LED light connector on the door handle assembly, and then install the LED harness fir tree clip.
  5. Install the bolts (x4) that attach the door handle back plate to the outer door grip (torque 2 Nm).
  6. Install a new door handle rear seal on the exterior door release handle assembly:
    1. Align the holes in the new door handle rear seal to the studs on the exterior door release handle assembly.
    2. Use a zip tie to attach the seal to the lower hole in the door handle assembly, and then cut the excess length of the zip tie.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      To avoid damage to the electrical harness, properly route the wires.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      To avoid damage to the seal, do not over-tighten the cable tie.
    3. Use a suitable tool, such as a socket extension, to press the outside edge of the seal firmly against the assembly.
    4. Use a deep 5 mm socket to press the push nuts (x4) onto the studs.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not use excessive force to press the push nuts onto the studs.
    5. Verify that each push nut is set onto its stud with no gap between the seal and assembly.
  7. Apply Loctite 222 onto the nuts (x4), install the door handle assembly to the front door assembly in the door body, and then hand tighten the nuts (x4).
  8. Use the door handle alignment tool to align the door handle.
  9. Make sure the front and rear of the door handle are flush with the outside of the door panel and the handle fit is consistent with other door handles on the vehicle.
    1. If the door handle alignment is correct, tighten the nuts (x4) to 9 Nm, and then go to the next step.
    2. If the door handle appearance is not consistent with the other handles installed on the vehicle, remove the nuts installed in step 7.
    3. To achieve a fit consistent with the other door handles on the vehicle, install or remove shims around the door handle mounting studs on the inboard side of the door panel until the correct fit is achieved.
      Informational PurposesAn informational icon, calling your attention
      Note
      To achieve the correct fit, 1 shim (1.5mm thick) on each door handle mounting stud is nominal. If necessary to achieve the correct fit, try combinations of 1 or 2 shims, up to a total of 3.0 mm total thickness for all shims on any of the 4 door handle mounting studs.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Failure to properly align the door handle with the outside of the door panel can result in improper fitment, and therefore repeat repair of the door handle.
    4. Tighten the nuts (x4) to 9 Nm.
  10. Remove the tape from the door handle grip.
  11. Connect the 3.0 door handle jumper harness to the LH front door handle assembly.
  12. Route the 3.0 LH front door handle jumper harness to clear the path of the window glass.
    Informational PurposesAn informational icon, calling your attention
    Note
    Remove the harness clip as the first generation doors do not have a hole for the clip.
    Informational PurposesAn informational icon, calling your attention
    Note
    Refer to the other pictures for reference on harness routing.
    Figure 1. Harness clip to be removed
  13. Connect the 3.0 door handle jumper harness to the LH front door harness and attach the fir tree clip at the connector onto the door assembly.
  14. Drill a 25 mm hole in the closeout panel where indicated.
    Informational PurposesAn informational icon, calling your attention
    Note
    The image shows the inboard side of the closeout panel.
  15. Insert the tabs on the bottom of the door handle module into the retainers on the closeout panel.
  16. Install and tighten the screw that attaches the top of the door handle module to the closeout panel (torque 2 Nm).
  17. Route the 3.0 LH front door handle jumper harness through the front door closeout panel and attach the grommet onto the closeout panel.
  18. Connect the door handle controller harness connector to the LH front 3.0 door handle assembly.
  19. Use the window switch tool to fully raise the LH front window regulator.
  20. Install the LH front door window glass and secure the locking tab.
  21. Install the outer belt seal. See Seal - Outer Belt - Front Door - LH (Remove and Replace).
  22. Confirm the LH front window alignment of the tape markings on the glass relative to the tape markings on the outer belt seal, and then torque the nut to secure the glass to the window regulator (torque 7.5 Nm).
  23. Remove the tape from the LH front window glass and outer belt seal.
  24. Carefully reinstall the inner door glass seal, starting from the rear part of the door, and moving towards the front.
  25. Verify the correct operation of the LH front window.
    Informational PurposesAn informational icon, calling your attention
    Note
    Cycle the LH front window while listening and looking for any contact between the regulator and wiring harness during operation. Make sure that the door handle harness and connectors are clear of the path of the regulator and moving glass.
  26. Install the screws (x6) that attach the closeout panel to the door frame (torque 4 Nm).
  27. Install the screws (x3) that attach the door controller to the closeout panel (torque 1 Nm).
  28. Disconnect the window switch tool.
  29. Reinstall the door tape and patches (x6) on the inner LH front door.
  30. Install the LH front door panel. See Panel - Door Trim - Front - LH (Remove and Install).
  31. Unlatch the LH front door.
  32. Perform the LH front door exterior release handle recalibration procedure through the touchscreen. See Handle - Exterior Release - Door (Recalibrate).
  33. Perform a firmware reinstall through the touchscreen. See Firmware Reinstall - Touchscreen.
  34. Exit Service Mode. See Service Mode.
  35. Verify the correct operation of all door handles.