Rear Door: Service and Repair
DISASSEMBLY1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG
a. Using a screwdriver wrapped with protective tape, disengage the 3 claws and remove the rear door inside handle bezel plug.
2. REMOVE REAR DOOR ARMREST BASE PANEL ASSEMBLY
a. Using a screwdriver wrapped with protective tape,disengage the 2 claws and 2 clips.
b. Disconnect the connector and remove the rear door armrest base panel assembly.
3. REMOVE REAR DOOR ARMREST COVER
a. Remove the rear door arm rest cover.
4. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY
a. Remove the 2 screws.
b. Pulling the front door trim board sub-assembly in the direction of the arrow shown in the illustration, disengage the 13 clips.
c. Disconnect the cable and each connector from the inside handle and remove the rear door trim board sub-assembly.
5. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER
a. Remove the rear door glass weatherstrip inner as shown in the illustration.
6. REMOVE REAR DOOR ARMREST SET BRACKET
a. Remove the 2 screws and the rear door armrest set bracket.
7. REMOVE REAR SPEAKER
8. REMOVE REAR DOOR SERVICE HOLE COVER
a. Disconnect each connector and remove the rear door service hole cover.
HINT: Remove the remaining tape on the door side.
9. REMOVE REAR DOOR GLASS RUN
a. Connect the window regulator switch assembly.
b. Fully lower the door glass.
c. Remove the rear door glass run.
10. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY
a. Remove the 2 bolts, the screw, and the rear door window division bar sub-assembly.
11. REMOVE REAR DOOR QUARTER WINDOW GLASS
a. Remove the rear door quarter window glass and the rear door quarter window weatherstrip as a unit as shown in the illustration.
b. Remove the rear door quarter window glass from the rear door quarter window weatherstrip.
12. REMOVE REAR DOOR GLASS SUB-ASSEMBLY
a. Remove the rear door glass sub-assembly from the rear door window regulator sub-assembly as shown in the illustration.
NOTE: Do not damage the door glass.
b. Disconnect the window regulator switch assembly.
13. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY
a. Disconnect the connector.
b. Loosen the temporary bolt.
NOTE: If the temporary bolt is removed, the rear door window regulator may fall and become deformed.
c. Remove the 3 bolts and the rear door window regulator sub-assembly and the power window regulator motor assembly rear as a unit.
d. Remove the temporary bolt from the regulator.
14. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR
a. Using a "torx" driver (T25), remove the 3 screws and the power window regulator motor assembly rear.
15. REMOVE REAR DOOR LOCK ASSEMBLY
a. Disconnect the connector.
b. Using a "torx" socket wrench (T30), remove the 3 screws.
c. Slide the rear door lock assembly downward, pull out the link from the outside handle frame, and remove the rear door lock assembly and cables as a unit.
16. REMOVE DOOR LOCK WIRING HARNESS SEAL
17. REMOVE REAR DOOR OUTSIDE HANDLE COVER
a. Using a "torx" socket wrench (T30), loosen the screw.
b. Disengage the 2 claws and remove the rear door outside handle cover.
18. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY
a. Pull and hold the release plate of the outside handle frame as shown in the illustration.
NOTE: The release plate may interfere with the outside handle and may be damaged when removing the handle, unless the release plate of the outside handle frame is pulled and held.
b. Remove the rear door outside handle assembly as shown in the illustration.
19. REMOVE REAR DOOR OUTSIDE HANDLE PAD
a. Disengage the 3 claws and remove the rear door outside handle pad.
20. REMOVE REAR DOOR OUTSIDE HANDLE PAD REAR
a. Disengage the 2 claws and remove the rear door outside handle pad rear.
21. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Using a "torx" socket wrench (T30), remove the screw and rear door outside handle frame subassembly.
22. REMOVE REAR DOOR CHECK COVER
a. Disengage the pin and remove the rear door check cover.
23. REMOVE REAR DOOR CHECK ASSEMBLY
a. Remove the bolt, 2 nuts, and the rear door check assembly.
24. REMOVE REAR DOOR WEATHERSTRIP
a. Remove the clip, disengage the 19 clips and remove the rear door weatherstrip.
25. REMOVE REAR DOOR BELT MOULDING ASSEMBLY
26. REMOVE REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY
REASSEMBLY
1. INSTALL REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY
2. INSTALL REAR DOOR BELT MOULDING ASSEMBLY
3. INSTALL REAR DOOR WEATHERSTRIP
4. INSTALL REAR DOOR CHECK ASSEMBLY
a. Install the rear door check assembly with the bolt and the 2 nuts.
bolt:
Torque: 27 N.m (275 kgf.cm, 20 ft.lbf)
nut:
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
5. INSTALL REAR DOOR CHECK COVER
6. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Apply body grease to the sliding parts on the rear door outside handle frame sub-assembly.
b. Using a "torx" socket wrench (T30), install the rear door outside handle frame sub-assembly with the screw.
7. INSTALL REAR DOOR OUTSIDE HANDLE PAD REAR
8. INSTALL REAR DOOR OUTSIDE HANDLE PAD
9. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY
10. INSTALL REAR DOOR OUTSIDE HANDLE COVER
a. Install the rear door outside handle cover with the 2 claws.
b. Using a "torx" socket wrench (T30), install the rear door outside handle cover with the screw.
11. INSTALL DOOR LOCK WIRING HARNESS SEAL
12. INSTALL REAR DOOR LOCK ASSEMBLY
NOTE:
- When reusing the removed rear door lock assembly, replace the door lock wire harness sealing on the connector with a new one.
- Do not allow grease or dust to adhere on the door lock wiring harness sealing surface of the connector.
- Reusing the door lock wiring harness sealing and or using damaged door lock wiring harness sealing may cause water intrusion to the connection, and result in a malfunction in the rear door lock assembly.
a. Apply body grease to the sliding parts on the rear door lock assembly.
b. Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.
c. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.
d. Using a "torx" socket wrench (T30), install the rear door lock assembly with the 3 screws.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
e. Connect the connector.
13. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY
NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.
a. Using a "torx" driver (T25), install the power window regulator motor assembly with the 3 screws.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
HINT: The new rear window regulator adopts a self tapping method. The installation position of regulator will be threaded when the self-tapping screw is inserted.
14. INSTALL REAR DOOR WINDOW REGULATOR SUBASSEMBLY
a. Apply body grease to the sliding parts on the rear door window regulator sub-assembly.
b. Install the temporary bolt to the rear door window regulator sub-assembly.
c. Tighten the 4 bolts and install the rear door window regulator sub-assembly.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
d. Connect the connector.
15. INSTALL REAR DOOR GLASS SUB-ASSEMBLY
16. INSTALL REAR DOOR QUARTER WINDOW GLASS
17. INSTALL REAR DOOR WINDOW DIVISION BAR SUBASSEMBLY
18. INSTALL REAR DOOR GLASS RUN
19. INSTALL REAR DOOR SERVICE HOLE COVER
a. Apply butyl tape to the rear door panel as shown in the illustration.
b. Install the rear door service hole cover.
20. INSTALL REAR SPEAKER
21. INSTALL REAR DOOR ARMREST SET BRACKET
22. INSTALL REAR DOOR GLASS WEATHERSTRIP INNER
23. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY
24. INSTALL REAR DOOR ARMREST COVER
25. INSTALL REAR DOOR ARMREST BASE PANEL ASSEMBLY
26. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG
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