Rear Door: Service and Repair

DISASSEMBLY OF REAR DOOR

1. REMOVE DOOR INSIDE HANDLE
(a) Remove the screw and slide the handle forward.
(b) Disconnect the control link and remove the handle.

2. REMOVE DOOR TRIM
(a) Remove the two screws from the armrest.
(b) Install a screwdriver between the retainers and door trim to pry it loose.

HINT: Tape the screwdriver tip before use.

(c) Disconnect the connector.

3. REMOVE SERVICE HOLE COVER
(a) Using a clip remover, remove the two screw grommets.
(b) Remove the service hole cover.

4. REMOVE WEATHERSTRIP
(a) Remove the screws and two clips.
(b) Using a clip remover, remove the nineteen clips.

5. REMOVE REAR DOOR BELT MOULDING
(a) Wind the glass down into the door cavity.
(b) Remove the screw.
(c) Pry loose the edge of the panel and remove the rear door belt moulding.

6. REMOVE DOOR GLASS

(a) Remove two bolts and rear door trim supports.
(b) Remove two bolts and door glass stoppers.

7. REMOVE REAR GLASS GUIDE
(a) While holding the stud bolt with the hexagon wrench 3 mm (0.118 in.), remove two nuts.
(b) Remove the nut and rear glass guide.

8. REMOVE FRONT GLASS GUIDE
Remove the bolt and three nuts and front glass guide.

9. REMOVE WINDOW REGULATOR
(a) Disconnect the connector from the motor.
(b) Remove two equalizer arm bracket mounting bolts.
(c) Remove four regulator mounting bolts.
(d) Remove the regulator through the service hole.

10. REMOVE OPENING CONTROL LINK AND INSIDE LOCKING LINK
Remove the bolt and disconnect the opening control link and inside locking link from the door lock.

11. REMOVE DOOR LOCK
(a) Remove the child protector cover.
(b) Disconnect the connector.
(c) Remove one bolt and three screws.
(d) Disconnect the control link from the door outside handle and remove the door lock with the door lock motor.

12. REMOVE DOOR OUTSIDE HANDLE
(a) Remove two screws and the outside handle protector.
(b) Remove two bolts and the door outside handle.

REPLACEMENT OF GLASS

1. REMOVE FOLLOWING PARTS:
(a) Roller
(b) Bolt
(c) Stabilizer
(d) Bracket
(e) Washers
(f) Nuts

2. INSTALL EACH PART TO GLASS

ASSEMBLY OF REAR DOOR

1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE

(a) Apply MP grease to the sliding surface and gears of the window regulator.

NOTICE: Do not apply MP grease to the spring of the window regulator.

(b) Apply MP grease to the sliding surface of the door lock.

2. INSTALL DOOR OUTSIDE HANDLE
(a) Install the door outside handle with two bolts.
(b) Install the outside handle protector with two screws.

3. INSTALL DOOR LOCK
(a) Install the door lock with three screws and one bolt.
(b) Install the child protector cover.
(c) Connect the connector.

4. INSTALL FOLLOWING LINKAGES:
- Opening control link
- Inside locking link

4. INSTALL WINDOW REGULATOR
(a) Place the regulator through the service hole.
(b) Temporarily tighten two equalizer arm bracket mounting bolts.
(c) Install four regulator mounting bolts.
(d) Connect the connector to the motor.

5. INSTALL REAR GLASS GUIDE
Install the rear glass guide with the lower nut (b) and temporarily tighten two upper nuts (a).

6. INSTALL FRONT GLASS GUIDE
Install the front glass guide with the lower nut (b) and temporarily tighten two upper nuts (a).

7. INSTALL DOOR GLASS
(a) Place the glass in the door cavity.
(b) Install the door glass to the regulator with two glass mounting nuts.

8. INSTALL TWO DOOR TRIM SUPPORTS
Install the door trim supports and temporarily tighten two bolts.

9. INSTALL TWO DOOR GLASS STOPPERS
Install the door glass stoppers and temporarily tighten two bolts.

10. INSTALL WINDOW BELT MOULDING
(a) Install the claw of the clips into the upper panel slit and push the belt moulding onto the panel.
(b) Install the screw.

11. ADJUST DOOR TRIM SUPPORTS
While pressing the claw of the door trim support to the door inner panel, tighten the bolt.

12. ADJUST DOOR GLASS

(a) (In left/right - upper side of glass)
Using a hexagon wrench 3 mm (0.11 8 in.), adjust the stud bolts (a) of the glass guide.
For example, if you turn both stud bolts clockwise, the upper side of the glass move to the outside.

HINT: Turn both stud bolts of the glass guide an equal amount.

(b) (In forward/rearward direction) Adjust the rear guide (b).
(c) (In vertical direction) Adjust the door glass stopper (c).
(d) (In lean of forward/rearward direction) Adjust the equalizer arm bracket mounting bolts (d).

13. TIGHTEN EACH BOLT, NUT OF EACH PART

14. CHECK DOOR GLASS
(a) When you close the door with the glass fully closed, check that the A-A, B- B sections are the same as the condition shown in the illustration.
(b) When you close the door with the glass fully closed, be careful that the glass is not caught in the weatherstrip.
(c) When you raise up the glass, check that the glass and the roof weatherstrip retainer are parallel and the front and rear door glass stoppers touch at the same time.
(d) When you raise up the glass to the middle, check that the gap of the glass is not big in the door trim support.
(e) Check that the glass moves smoothly.
If the above conditions are not met, readjust the glass.

15. INSTALL SERVICE HOLE COVER
(a) Install the service hole cover with adhesive.
(b) Install the lower edge of the cover into the panel slit.
(c) Seal the panel slit with cotton tape.

NOTICE: Do not block the trim clip seating holes with the tape.

(d) Install two screw grommets.

16. INSTALL DOOR TRIM
(a) Connect the connector.
(b) Install the door trim with clips to the inside door panel by tapping.
(c) Install two screws and covers.

17. INSTALL INSIDE HANDLE
(a) Connect the handle to the control link.
(b) Slide the handle rearward and install the screw.