Rear Door: Service and Repair
DISASSEMBLY
1. REMOVE INSIDE HANDLE BEZEL
a. Using a screwdriver, open the screw cap.
HINT: Tape the screwdriver tip before use.
b. Remove the screw.
c. Using a screwdriver, remove the inside handle bezel as shown in the illustration.
HINT: Tape the screwdriver tip before use.
2. REMOVE POWER WINDOW SWITCH
a. Using a screwdriver, remove the power window switch.
HINT: Tape the screwdriver tip before use.
b. Disconnect the connector.
3. REMOVE REAR ARMREST
a. Remove the screw.
b. Using a screwdriver, remove the rear armrest.
HINT: Tape the screwdriver tip before use.
4. REMOVE DOOR TRIM
Using a screwdriver, disengage the clips, then pull the trim upward to remove it.
HINT: Tape the screwdriver tip before use.
5. REMOVE INSIDE HANDLE
Remove the screw and inside handle, disconnect the 2 cables from the inside handle.
6. REMOVE SERVICE HOLE COVER
a. Disconnect the connector.
b. Remove the 2 screws and door trim bracket.
c. Remove the service hole cover.
7. REMOVE SERVICE HOLE PLATE
Remove the 2 screws and service hole plate.
8. REMOVE DOOR GLASS RUN
9. REMOVE REAR DOOR BELT MOULDING
a. Remove a screw.
b. Apply protective tape to the outer surface as shown in the illustration to keep the surface from being scratched.
c. Using a moulding remover, remove the rear door belt moulding as shown in the illustration.
10. REMOVE DIVISION BAR
a. Remove the 2 bolts and screw.
b. Pull the division bar forward.
c. Rotate the division bar 9O degrees and pull it upward as shown in the illustration.
11. REMOVE REAR DOOR QUARTER WINDOW GLASS
a. Remove the rear door quarter window glass as shown in the illustration.
NOTE: Do not damage the glass.
b. Remove the quarter window weatherstrip from the glass.
12. REMOVE DOOR GLASS
HINT: Insert a shop rag inside the door panel to prevent scratching the glass.
a. Open the door glass.
b. Tilt the door glass and disconnect the roller of the regulator from the glass channel to remove the door glass.
13. REMOVE WINDOW REGULATOR
a. Disconnect the connector.
b. Remove the 4 bolts and window regulator.
14. REMOVE DOOR LOCK
a. Remove the child protection cover.
b. Disconnect the 2 links from the outside handle and key cylinder.
c. Remove the bolt and screw.
d. Using a torx socket wrench, remove the 3 torx screws and door lock.
Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
HINT: Remove the door lock through the service hole.
e. Disconnect the connector.
15. REMOVE OUTSIDE HANDLE
Remove the 2 bolts, rear door outside reinforcement extension and outside handle.
16. REMOVE CUSHIONS
REASSEMBLY
1. INSTALL CUSHIONS
2. INSTALL OUTSIDE HANDLE
Install the outside handle and rear door outside reinforcement extension with the 2 bolts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
3. INSTALL DOOR LOCK
a. Connect the connector.
b. Using a torx socket wrench, install the door lock with the 3 torx screws.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
Torx socket wrench: T30 (Part No. 09042-00010 or locally manufactured tool)
HINT: Apply adhesive to the 3 torx screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
c. Install the bolt and screw.
d. Connect the 2 links to the outside handle and key cylinder.
e. Install the child protection cover.
4. INSTALL WINDOW REGULATOR
HINT: Apply MP grease to the sliding and rotating parts of the window regulator.
a. Install the window regulator with the 4 bolts.
Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)
b. Connect the connector.
5. INSTALL DOOR GLASS
HINT: Insert a shop rag inside the door panel to prevent scratching the glass. Tilt the door glass and connect the roller of the regulator to the glass channel to install the door glass.
6. INSTALL QUARTER WINDOW GLASS
a. Install the quarter window weatherstrip to the glass.
NOTE: Do not damage the glass.
b. Install the rear door quarter window glass as shown in the illustration.
7. INSTALL DIVISION BAR
a. Insert the division bar to the door panel, then rotate it 90°.
b. Install the 2 bolts and screw.
8. INSTALL DOOR GLASS RUN
9. INSTALL REAR DOOR BELT MOULDING
Install the rear door belt moulding with the screw.
10. INSTALL SERVICE HOLE PLATE
Install the service hole plate with the 2 screws.
11. INSTALL SERVICE HOLE COVER
a. Install the service hole cover to the door panel.
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, sealing condition shall be confirmed.
b. Install the door trim bracket with the 2 screws.
c. Connect the connector.
12. INSTALL INSIDE HANDLE
Connect the 2 cables to the inside handle, then install the inside handle with the screw.
NOTE: At the time of locking cable reassembly, please observe to the following items.
- Set the door lock assembly to the LOCK position.
- Hold the lock knob to the LOCK position by hand and do not pull the cable, while connecting the locking cable.
13. INSTALL DOOR TRIM
Install the door trim to the door panel.
14. INSTALL REAR ARMREST
Install the rear armrest with the screw.
15. INSTALL POWER WINDOW SWITCH
a. Connect the connector.
b. Install the power window switch to the door trim.
16. INSTALL DOOR INSIDE HANDLE BEZEL
a. Install the door inside handle bezel with the screw.
b. Close the cap.