Disassembly and Reassembly
REAR DOOR DISASSEMBLY
1. REMOVE DOOR INSIDE HANDLE BEZEL
(a) Using a screwdriver, pry out the bezel.
HINT: Tape the screwdriver tip before use.
(b) Pull the bezel rearwards to remove it.
2. REMOVE DOOR TRIM
(a) Remove the armrest cover and the screw.
(b) Remove three clips.
(c) Insert the screwdriver between the panel and the trim remove the clips.
(d) Pull the trim upwards to remove it.
(e) Disconnect the connector.
(f) Remove three screws and the armrest base panel.
3. REMOVE DOOR BELT MOULDING
4. REMOVE DOOR WEATHERSTRIP
(a) Remove two clips.
(b) While pulling the weatherstrip by hand, remove the eighteen clips using a clip remover.
HINT: Do not pull strongly on the weatherstrip as it may tear.
5. REMOVE SIDE PROTECTION MOULDING
6. REMOVE DOOR INSIDE HANDLE
(a) Remove three screws.
(b) Disconnect the two links from the handle.
7. REMOVE SERVICE HOLE COVER
8. REMOVE REAR DOOR UPPER STOP
Remove two bolts and the stops.
9. REMOVE REAR DOOR SUPPORT
Remove two bolts and the support.
10. REMOVE DOOR GLASS
HINT: Insert a shop rag inside the panel to prevent scratching the glass.
(a) Remove two glass mounting bolts.
(b) Remove the door glass by pulling it upward.
11. REMOVE DOOR INSIDE PANEL PLATE
Remove the bolt and the plate.
12. REMOVE WINDOW REGULATOR
(a) Remove eight nuts and the regulator.
(b) Disconnect the connector.
13. REMOVE GUIDE UPPER PLATE
Remove the bolt and the plate.
14. REMOVE WINDOW REAR GUIDE
Remove three nuts and the guide.
15. REMOVE CHILD PROTECTOR LOCK LEVER KNOB
Using a screwdriver. remove the knob.
HINT: Tape the screwdriver tip before use.
16. REMOVE OPENING CONTROL LINK AND INSIDE LOCKING LINK
(a) Remove the clip and the protect cover.
(b) Disconnect two links from the door lock and remove two links.
17. REMOVE DOOR LOCK
(a) Remove four screws.
(b) Disconnect the connector.
(c) Remove the door lock through the service hole.
18. REMOVE OUTSIDE HANDLE
Remove two bolts and the outside handle.
19. REMOVE DOOR INSIDE PANEL FRAME
Remove three screws and the frame.
DOOR GLASS REPLACEMENT
1. REMOVE FOLLOWING PARTS:
(a) Stopper
(b) Stabilizers
(c) Bracket
2. REPLACE DOOR GLASS
3. INSTALL DOOR GLASS PARTS
Install the parts by following removal sequence in reverse.
REAR DOOR ASSEMBLY
1. BEFORE INSTALLATION PARTS, COAT THEM WITH MP GREASE
(a) Apply MP grease to the sliding surface and gears of the window regulator.
(b) Apply MP grease to the sliding surface of the door lock.
2. INSTALL OUTSIDE HANDLE
Install the handle with two bolts.
3. INSTALL DOOR LOCK
(a) Apply adhesive to three screws.
Part No.08833-00070, THREE BOND 1324 or equivalent
(b) Install the door lock with three screws.
Torque: 6.4 N.m (55 kgf.cm. 48 in.Ibf)
(c) Install the bolt.
(d) Connect the connector.
4. INSTALL OPENING CONTROL LINK AND INSIDE LOCKING LINK
(a) Connect two links to the door lock.
(b) Install the clip and the protector.
5. INSTALL CHILD PROTECTOR LOCK LEVER KNOB
Install the knob.
6. INSTALL DOOR INSIDE PANEL FRAME
Install the frame with three screws.
7. INSTALL DOOR INSIDE PANEL PLATE
Install the plate with the bolt.
8. INSTALL WINDOW REAR GUIDE
Install the guide with three nuts.
9. INSTALL GUIDE UPPER PLATE
Install the plate with the bolt.
10. INSTALL WINDOW REGULATOR
Install the regulator with eight nut.
11. INSTALL DOOR GLASS
HINT: Insert a shop rag inside the panel to prevent scratching the glass.
(a) Insert the glass to the frame.
(b) Temporarily tighten two glass mounting bolts.
12. INSTALL REAR DOOR SUPPORT
Install the support with the bolt.
13. INSTALL DOOR UPPER STOP
Install the stop with the bolt.
14. ADJUST REAR DOOR GLASS
(a) Adjust lateral position of upper part of door glass.
- Remove bolt (A) and remove upper plate.
- Loosen two nuts (B).
- Loosen two nuts (C). then adjust the stud bolts using a hexagon wrench.
(b) Adjust the front/rear position of the door glass.
- Loosen the two bolts (D), then adjust the door glass.
(c) Adjust the inclination of the rear end of the door glass.
- Loosen the two bolts (D).
(d) Adjust the glass in the vertical direction.
- Loosen the two bolts (E) and adjust the upper stopper vertically.
(e) Tighten the two nuts (B) until they touch the panel.
(f) Install the upper plate with the bolt.
(g) After adjustment is performed. check the following items:
- When the door is closed with the door glass then fully closed or else the door glass is fully closed with the door then closed, check that cross-section A-A and B-B are as specified in the illustration.
- When the door glass is fully closed and the door then closed, check that the weatherstrip is not pinched and that the door glass is not in contact with the roof drip moulding.
- When the door glass is fully closed, check that the outside edge of the door glass is in contact with the weatherstrip at the front pillar and roof side and that the edge of the glass cannot be seen.
- Check that the door glass is not loose when it is half open.
- When the door glass is rising up, check that the door glass and roof side weatherstrip are parallel and that the door glass contacts the two upper plates.
- Check that the door glass moves up and down smoothly over all areas.
15. INSTALL SERVICE HOLE COVER
Seal the service hole cover with adhesive.
16. INSTALL SIDE PROTECTION MOULDING
17. INSTALL DOOR INSIDE HANDLE
(a) Connect two links with the handle.
(b) Install the handle with three screws.
18. INSTALL DOOR WEATHERSTRIP
(a) Push down on the nineteen clips and install the weatherstrip.
(b) Install two clips.
19. INSTALL DOOR BELT MOULDING
20. INSTALL DOOR TRIM
(a) Install the armrest base panel with three screws.
(b) Insert the upper edge of the trim from above, tap the trim by hand fix it in place the clips, then connect the connectors.
(c) Install three clips.
21. INSTALL DOOR INSIDE HANDLE BEZEL
Tap the bezel to install it.