Door System: Removal & Installation Honda Insight ZE1

Door Panel Removal/Installation

Special Tools Required

1. KTC trim tool set SOJATP2014 *
2. Trim pad remover Snap-on A 177A or equivalent, commercially available * Available through the American Honda Tool and Equipment Program; call 888-424-6857

Note. Take care not to scratch the door panel and door. Use the appropriate tool from the KTC trim tool set to avoid damage when prying components.

Scheme 8

1. Remove the mirror mount cover (see «POWER MIRROR REPLACEMENT»(ref-219311-S37228555692006021300000) ).
2. Remove the door panel in the numbered sequence. Remove the door panel with as little bending as possible to avoid creasing or breaking it.
3. Install the panel in the reverse order of removal, and note these items: Check for damaged or stress-whitened clips, and replace them with new ones. Make sure the connectors are plugged in properly. Check the window and power door lock operations.

Door Outer Handle Replacement

Note. Put on gloves to protect your hands. Take care not to scratch the door. Take care not to bend each rod.

Scheme 9

Scheme 10

1. Raise the glass fully, and remove these items: Door panel (see «DOOR PANEL REMOVAL/INSTALLATION»(ref-219310-S00758574062006021300000) ) Plastic cover, as necessary (see «COMPONENT LOCATION INDEX»(ref-219310-S09234864442006021300000) )
2. Remove the door outer handle in the numbered sequence.
3. Install the handle in the reverse order of removal, and note these items: When installing the lock cylinder, leave the outer handle bolts loose so the outer handle protector does not interfere with the lock cylinder installation, then tighten the handle bolts. Install the retainer clip on the outer handle, then install the lock cylinder. Be sure the retainer clip is fully seated in the slot on the lock cylinder. Make sure the door locks and opens properly. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter.

Door Latch Replacement

Note. Put on gloves to protect your hands. Take care not to scratch the door. Take care not to bend each rod.

Scheme 11

1. Remove the outer handle (see «DOOR OUTER HANDLE REPLACEMENT»(ref-219310-S08696511622006021300000) ).
2. Remove the door latch in the numbered sequence.
3. Install the latch in the reverse order of removal, and note these items: Make sure the actuator connectors are plugged in properly, and each rod is connected securely. Make sure the door locks and opens properly. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter.

Door Glass and Regulator Replacement

Note. Put on gloves to protect your hands. Take care not to scratch the door. Take care not to drop the window glass inside the door.

Scheme 12

Scheme 13

1. Remove these items: Door panel (see «DOOR PANEL REMOVAL/INSTALLATION»(ref-219310-S00758574062006021300000) ) Plastic cover (see «COMPONENT LOCATION INDEX»(ref-219310-S09234864442006021300000) )
2. Remove the door glass and regulator in the numbered sequence.
3. Install the door glass and regulator in the reverse order of removal, and note these items: Before installing the regulator, apply multipurpose grease to all the sliding surfaces of the regulator. Make sure the connector is plugged in properly. Roll the glass up and down to see if it moves freely without binding. Make sure that there is no clearance between the glass and glass run channel when the glass is closed. Adjust the position of the glass as necessary (see «DOOR GLASS ADJUSTMENT»(ref-219310-S00279813972006021300000) ). Check for water leaks (see step 7 ). Test-drive and check for wind noise and rattles. When reinstalling the door panel, make sure the plastic cover is installed properly and sealed around its perimeter.

Door Sash Outer Trim Replacement

Note. Take care not to scratch the door and trim. Use a clip remover to remove the door upper seal clips.

Scheme 14

1. Remove the door sash outer trim as shown.
2. Install the trim in the reverse order of removal, and note these items: Install the bottom of the trim into the door molding securely. Check for damaged or stress-whitened clips, and replace them with new ones.

Door Glass Outer Weatherstrip Replacement

Note. Put on gloves to protect your hands. Take care not to scratch the door and molding.

Scheme 15

1. Remove these items: Door sash outer trim Power mirror (see «POWER MIRROR REPLACEMENT»(ref-219311-S37228555692006021300000) )
2. Starting at the rear, pry the door glass outer weatherstrip (A) up, and detach the clips (B).
3. Install the weatherstrip in the reverse order of removal, and check for damaged or stress-whitened clips, and replace them with new ones.

Door Seal and Door Weatherstrip Spacer Replacement

Note. Take care not to scratch the door. Use a clip remover to remove the clips.

Scheme 16

1. Remove these items: Before removing the door upper seal, remove the door panel (see «DOOR PANEL REMOVAL/INSTALLATION»(ref-219310-S00758574062006021300000) ) and door sash outer trim (see «DOOR SASH OUTER TRIM REPLACEMENT»(ref-219310-S35631885332006021300000) ). Before removing the door weatherstrip spacer, remove the door panel (see «DOOR PANEL REMOVAL/INSTALLATION»(ref-219310-S00758574062006021300000) ).
2. Remove the door upper seal, door still seal, and door weatherstrip spacer as shown.
3. Install the seals and spacer in the reverse order of removal, and note these items: Check for damaged or stress-whitened clips, and replace them with new ones. If the old upper seal and spacer are to be reinstalled, scrape off all traces of old butyl tapes, EPT sealer, and adhesive tape, then clean the upper seal and spacer surfaces with alcohol. Attach the new butyl tapes, EPT sealer, and adhesive tape to the door upper seal and door weatherstrip spacer. Press the butyl tape and adhesive tape portions to make the adhesive stick. Check for water leaks (see step 7 ). Test-drive and check for wind noise.