Trunk / Liftgate: Service and Repair

BACK DOOR

Back Door:

DISASSEMBLY

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. With 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
a. Remove the back door service hole cover.

NOTICE: Remove the remaining tape on the door side.

9. REMOVE STEREO COMPONENT SPEAKER ASSEMBLY (WITH REAR 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 WITH MOTOR BACK DOOR LOCK ASSEMBLY
a. Disconnect the door lock 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 LIGHT 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.

REASSEMBLY

1. INSTALL BACK DOOR STAY BRACKET SUB-ASSEMBLY RH
a. Install the back door stay bracket sub-assembly with the 2 bolts.

Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)

2. 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 N.m (184 kgf.cm, 13 ft.lbf)

c. Install the top set bolt cap B.

3. INSTALL BACK DOOR LINK SUB-ASSEMBLY LOWER
a. Install the link sub-assembly with the bolts.

Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)

4. INSTALL BACK DOOR SIDE FEMALE STOPPER SUB-ASSEMBLY RH
a. Install the female stopper with the 2 bolts.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)

5. INSTALL WITH 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.

NOTICE:
- 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 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.

NOTICE: 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 N.m (51 kgf.cm, 42 in.lbf)

f. Connect the door lock connector.

6. INSTALL BACK DOOR OUTSIDE HANDLE
a. Install the handle with the 2 bolts.

Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)

7. INSTALL STEREO COMPONENT SPEAKER ASSEMBLY (WITH REAR SPEAKER)
8. INSTALL BACK DOOR SERVICE HOLE COVER (WITH REAR 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.

c. Install the 2 tool box brackets with the 4 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)