Trunk / Liftgate: Service and Repair
BACK DOOROVERHAUL
HINT: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
1. REMOVE BACK DOOR GARNISH CENTER
a. Using a clip remover, disengage the 5 clips, and remove the garnish center.
2. REMOVE BACK DOOR SIDE GARNISH LH
a. Using a clip remover, disengage the 3 clips, and remove the side garnish.
3. REMOVE BACK DOOR SIDE GARNISH RH
a. Using a clip remover, disengage the 3 clips, and remove the side garnish.
4. REMOVE TOOL BOX PANEL SUB-ASSEMBLY UPPER
a. Remove the tool cover and tool set.
5. REMOVE ASSIST GRIP ASSEMBLY
a. Remove the 2 assist grip covers and assist grip assembly.
6. REMOVE BACK DOOR TRIM BOARD
a. Remove the 2 trim board covers.
b. Remove the screw.
c. Using a screwdriver, disengage the 15 clips and remove the trim board.
HINT: Tape the screwdriver tip before use.
d. Remove the 7 screws and trim pocket.
e. W/ Speaker
Remove the 4 screws and rear speaker grille sub-assembly LH and RH.
7. REMOVE BACK DOOR STOPPER LOWER
a. Remove the packing.
b. Using a screwdriver, disengage the claw, and remove the stopper lower.
8. REMOVE BACK DOOR SERVICE HOLE COVER
NOTE: Remove the remaining tape on the door side.
9. REMOVE STEREO COMPONENT SPEAKER ASSEMBLY (W/ SPEAKER)
10. REMOVE BACK DOOR OUTSIDE HANDLE
a. Remove the 2 bolts and outside handle.
b. Remove the cable.
HINT: Remove the outside handle through the service hole.
11. REMOVE W/MOTOR BACK DOOR LOCK ASSEMBLY
a. Disconnect the door look connector.
b. Using a torx socket wrench (T30), remove the 3 screws and door lock assembly.
HINT: Remove the door lock assembly through the service hole.
12. REMOVE LICENSE REAR LAMP COVER
13. REMOVE BACK DOOR GARNISH SUB-ASSEMBLY OUTSIDE
14. REMOVE REAR WIPER MOTOR ASSEMBLY
15. REMOVE BACK DOOR SIDE FEMALE STOPPER SUB-ASSEMBLY RH
a. Remove the 2 bolts and female stopper sub-assembly.
16. REMOVE BACK DOOR LINK SUB-ASSEMBLY LOWER
a. Remove the top set bolt cap B.
b. Remove the bolt and back door link sub-assembly.
17. REMOVE BACK DOOR STAY RAIL SUB-ASSEMBLY RH
a. Remove the 2 bolts and stay rail sub-assembly.
18. REMOVE REAR BUMPER COVER
19. REMOVE BACK DOOR STAY BRACKET SUB-ASSEMBLY RH
a. Remove the 2 bolts and stay bracket sub-assembly.
20. INSTALL BACK DOOR STAY BRACKET SUB-ASSEMBLY RH
a. Install the back door stay bracket sub-assembly with the 2 bolts.
Torque: 18 Nm (184 kgf.cm, 13 ft.lbf)
21. INSTALL BACK DOOR STAY RAIL SUB-ASSEMBLY RH
a. Apply MP grease to the sliding parts of the stay rail sub-assembly, as shown in the illustration.
b. Install the stay rail sub-assembly with the 2 bolts.
Torque: 18 Nm (184 kgf.cm, 13 ft.lbf)
c. Install the top set bolt cap B.
22. INSTALL BACK DOOR LINK SUB-ASSEMBLY LOWER
a. Install the link sub-assembly with the bolts.
Torque: 18 Nm (184 kgf.cm, 13 ft.lbf)
23. INSTALL BACK DOOR SIDE FEMALE STOPPER SUB-ASSEMBLY RH
a. Install the female stopper with the 2 bolts.
Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)
24. INSTALL W/MOTOR BACK DOOR LOCK ASSEMBLY
a. Apply MP grease to the sliding and rotating parts of the door lock assembly.
b. If reusing door lock assembly:
Install a new door lock wire harness packing.
NOTE:
- If reusing the door lock that has been removed, replace the packing in the connecting part with a new one.
- Be careful that no grease and dirt sticks to the packing surface in the connecting part.
- Reusing removed packing that is or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.
c. Insert the outside handle link into the door lock, and then set it to the door panel.
NOTE: Make sure that the outside handle link is securely engaged with the lock assembly.
d. Apply adhesive to the threads of the screws.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
e. Using a torx socket wrench (T30), install the door lock assembly with the 3 screws.
Torque: 5.0 Nm (51 kgf.cm, 42 in.lbf)
f. Connect the door lock connector.
25. INSTALL BACK DOOR OUTSIDE HANDLE
a. Install the handle with the 2 bolts
Torque: 5.0 Nm (51 kgf.cm, 42 in.lbf)
26. INSTALL STEREO COMPONENT SPEAKER ASSEMBLY(W/ SPEAKER)
27. INSTALL BACK DOOR SERVICE HOLE COVER (W/ SPEAKER)
a. Apply butyl tape to the door, as shown in the illustration.
Adhesive: Part No.08850-00065, Butyl Tape Set or equivalent
b. Install the service hole cover.
HINT:
- When installing the service hole cover, pull out the links and connectors through the service hole cover
- There should be no wrinkles or folds after attaching the service hole cover.
- After attaching the service hole cover, confirm the sealing condition
Dimensions:
c. Install the 2 tool box brackets with the 4 bolts.
Torque: 8.0 Nm (81 kgf.cm, 71 in.lbf)