Rear Door: Service and Repair

DISASSEMBLY




1. REMOVE NO. 2 DOOR INSIDE HANDLE BEZEL
Using a screwdriver, remove the No. 2 door inside handle bezel.

HINT: Tape the screwdriver tip before use.




2. REMOVE ARMREST BASE PANEL ASSEMBLY
a. Using a screwdriver, pry the armrest base panel assembly out.

HINT: Tape the screwdriver tip before use.

b. Disconnect the connector and ash receptacle light, and remove the armrest base panel assembly.
c. Remove the screw and upper armrest base panel.




3. REMOVE COURTESY LIGHT ASSEMBLY
a. Using a screwdriver, pry the courtesy light assembly out.
b. Disconnect the connector and remove the courtesy light assembly.




4. w/o Rear side curtain:
REMOVE NO. 2 DOOR FRAME GARNISH
Using a screwdriver, remove the No. 2 door frame garnish.

HINT: Tape the screwdriver tip before use.




5. w/ Rear side curtain:
REMOVE REAR SIDE CURTAIN ASSEMBLY
Using a screwdriver, remove the rear side curtain assembly.

HINT: Tape the screwdriver tip before use.




6. REMOVE DOOR TRIM
a. Remove the 6 screws.
b. Using a screwdriver, disengage the clips, then pull the trim upward to remove it.

HINT: Tape the screwdriver tip before use.

c. Disconnect the connectors.




d. Disconnect the 2 cables from the inside handle and remove the door trim.




7. REMOVE INSIDE DOOR HANDLE
a. Remove the screw.
b. Using a screwdriver, disengage the 2 claws and remove the inside door handle.

HINT: Tape the screwdriver tip before use.

c. Remove the No. 1 illumination light assembly.
d. w/ Seat memory:
Remove the seat memory switch.

8. w/ Tweeter:
REMOVE TWEETER SPEAKER
Remove the 3 screws and tweeter speaker from the door trim.




9. w/ Rear curtain:
REMOVE REAR CURTAIN SUB-ASSEMBLY
Remove the 4 screws and rear curtain sub-assembly.

10. REMOVE DOOR FRAME GARNISH
Remove the 2 clips and door frame garnish.

11. REMOVE DOOR SPEAKER
a. Disconnect the connector.
b. Remove the 3 screws and door speaker.

12. REMOVE DOOR ECU
a. Disconnect the connectors.
b. Remove the 2 screws and door ECU.




13. REMOVE SERVICE HOLE COVER




14. REMOVE DOOR BELT MOULDING
a. Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched.
b. Using a moulding remover, remove the door belt moulding.




15. REMOVE DOOR WINDOW REAR GUIDE SUB-ASSEMBLY AND DOOR GLASS RUN
a. Open the door glass to the lowest position.
b. Remove the 2 nuts and bolt.




c. Using a drill of less than dia 4 mm (0.16 in.).
d. Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.

NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or the drill Itself.
- Be careful when undertaking this task as the cut rivet is hot.

e. Even if flange is taken off, continue drilling and push cut remaining fragment with the drill.




f. Remove the door glass run together with door window rear guide sub-assembly.




16. REMOVE DOOR GLASS

HINT: Insert a shop rag inside the door panel to prevent scratching the glass.

a. Open the door glass until the nuts appear in the service hole.
b. Remove the 2 nuts and pull the glass upward to remove it.

NOTE: Do not damage the door glass.

c. Remove the glass channel sub-assembly and glass channel filler.




17. REMOVE WINDOW REGULATOR
a. Disconnect the connector.
b. Remove the 4 bolts.
c. Remove the regulator through the service hole.




18. REMOVE WINDOW REGULATOR MOTOR
a. Place the matchmarks on the window regulator motor bracket and regulator gear.
b. Using a torx wrench, remove the 3 screws and motor.

NOTE: Do not rotate the motor only.




19. REMOVE DOOR WINDOW FRONT GUIDE SUB-ASSEMBLY
a. Remove the 2 bolts.
b. Pull down the door window front guide sub-assembly to remove it.




20. 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.




21. w/o Door closer:
REMOVE DOOR LOCK

a. Disconnect the connector.
b. Using a torx wrench, remove the 3 screws and door lock through the service hole.
c. Remove the door lock remote control cable and door inside locking cable.




22. w/ Door closer:
REMOVE DOOR CLOSER

a. Disconnect the connector and wire harness clamps.
b. Using a torx wrench, remove the 4 screws and door closer through the service hole.
c. Remove the door lock remote control cable and door inside locking cable




23. REMOVE OUTSIDE HANDLE PLUG, OUTSIDE HANDLE AND OUTSIDE HANDLE FRAME
a. Remove the bolt and outside handle plug.
b. Remove the outside handle rear pad.




c. Hold the outside handle frame with your hand, and slide the outside handle rearward to remove it.

NOTE: Do not damage the body surface.

d. Remove the outside handle front pad.




e. Remove the nut and outside handle frame.

24. REMOVE NO. 2 REAR DOOR WEATHERSTRIP
Remove the clip and No. 2 rear door weatherstrip.




25. REMOVE WINDOW FRAME UPPER MOULDING
a. Using a drill of less than dia 4 mm (0.16 in.).
b. Gently and vertically place the drill tip onto the rivet, and cut the rivet flanges.

NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or the drill itself.
- Be careful when undertaking this task as the cut rivet is hot.

c. Even if flange is taken off, continue drilling and push cut remaining fragment with the drill.
d. Remove the window frame upper moulding.




26. REMOVE WINDOW FRAME FRONT MOULDING
Remove the 3 screws and window frame front moulding.

27. REMOVE REAR DOOR WEATHERSTRIP

REASSEMBLY

1. INSTALL REAR DOOR WEATHERSTRIP




2. INSTALL WINDOW FRAME FRONT MOULDING
Install the window frame front moulding with the 3 screws.




3. INSTALL WINDOW FRAME UPPER MOULDING
Using an air riveter with nose piece No. 1, install 6 new rivets and moulding.

NOTE:




- Prizing a riveter leads to damage to the riveter, loose tightening and bending the mandrel.




- Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the material.




- Loose tightening also occurs when a rivet is applied between materials without touching.

4. INSTALL NO. 2 REAR DOOR WEATHERSTRIP
Install the No. 2 rear door weatherstrip with the clip.




5. INSTALL OUTSIDE HANDLE PLUG, OUTSIDE HANDLE AND OUTSIDE HANDLE FRAME
a. Install the outside handle frame with the nut.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

b. Install the outside handle front pad.




c. Hold the outside handle frame with your hand, and slide the outside handle forward to install it.

NOTE: Do not damage the body surface.

d. Install the outside handle rear pad.




e. Install the outside handle plug with the bolt.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)




6. w/o Door closer:
INSTALL DOOR LOCK

HINT: Apply MP grease to the sliding and rotating parts of the door lock.

a. Install the door lock remote control cable and door inside locking cable.




b. Using a torx wrench, install the 3 screws and door lock.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

HINT: Apply adhesive to the 3 torx screws.

Part No. 08833-00070, THREE BOND 1324 or equivalent

c. Connect the connector.




7. w/ Door closer:
INSTALL DOOR CLOSER

HINT: Apply MP grease to the sliding and rotating parts of the door closer.

a. Install the door lock remote control cable and door inside locking cable.




b. Using a torx wrench, install the 4 screws and door closer.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

HINT: Apply adhesive to the 4 torx screws.

Part No. 08833-00070, THREE BOND 1324 or equivalent

c. Connect the connector and wire harness clamps.




8. INSTALL REAR DOOR QUARTER WINDOW GLASS
a. Install the quarter window weatherstrip to the glass.
b. Install the rear door quarter window glass as shown in the illustration.

NOTE: Do not damage the glass.




9. INSTALL DOOR WINDOW FRONT GUIDE SUB-ASSEMBLY
Install the door window front guide sub-assembly with the 2 bolts.

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

10. INSTALL WINDOW REGULATOR MOTOR

NOTE: If having rotated the motor only, reset the motor.

HINT: Never rotate the motor to the down direction until the complete of the window glass installation.




a. Align the matchmarks on the window regulator motor bracket and regulator gear.
b. Using a torx wrench, install the 3 screws and motor.




11. INSTALL WINDOW REGULATOR

HINT: Apply MP grease to the sliding and rotating parts of the window regulator.




a. Install the regulator through the service hole with the 4 bolts.

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

b. Connect the connector.




12. INSTALL DOOR GLASS

HINT: Insert a shop rag inside the door panel to prevent scratching the glass.

a. Install the glass channel filler and glass channel sub-assembly.
b. Put the door glass in the door panel carefully.

NOTE: Do not damage the door glass.

c. Install the door glass to the window regulator with the 2 nuts.

Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)

13. INSTALL DOOR WINDOW REAR GUIDE SUB-ASSEMBLY AND DOOR GLASS RUN
a. Install the door window rear guide sub-assembly to the door glass run.




b. Install the door glass run together with door window rear guide sub-assembly.




c. Install the 2 nuts and bolt.

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




d. Using an air riveter with nose piece No. 1, install 3 new rivets and glass run.

NOTE:




- Prizing a riveter leads to damage to the riveter, loose tightening and bending the mandrel.




- Loose tightening may result from either tilting the riveter while handling or the riveter not connecting to the material.




- Loose tightening also occurs when a rivet is applied between materials without touching.




14. INSTALL DOOR BELT MOULDING
Install the door belt moulding as shown in the illustration.




15. INSTALL SERVICE HOLE COVER
16. INSTALL DOOR ECU
a. Install the door ECU with the 2 screws.
b. Connect the connectors.

17. INSTALL DOOR SPEAKER
a. Install the door speaker with the 3 screws.
b. Connect the connector.

18. INSTALL DOOR FRAME GARNISH
Install the door frame garnish with the 2 clips.




19. w/ Rear curtain:
INSTALL REAR CURTAIN SUB-ASSEMBLY
Install the rear curtain sub-assembly with the 4 screws.

20. w/ Tweeter:
INSTALL TWEETER SPEAKER
Install the tweeter speaker to the door trim with the 3 screws.

21. INSTALL INSIDE DOOR HANDLE
a. w/ Seat memory:
Install the seat memory switch to the inside handle bezel.
b. Install the No. 1 illumination light assembly to the inside handle bezel.
c. Engage the 2 claws and install the inside door handle.
d. Install the screw.




22. INSTALL DOOR TRIM
a. Connect the 2 cables to the inside handle of the door trim.
b. Connect the connectors.




c. Install the door trim with the 6 screws.

23. w/o Rear side curtain:
INSTALL NO. 2 DOOR FRAME GARNISH

24. w/ Rear side curtain:
INSTALL REAR SIDE CURTAIN ASSEMBLY

25. INSTALL COURTESY LIGHT ASSEMBLY




26. INSTALL ARMREST BASE PANEL ASSEMBLY
a. Install the upper armrest base panel with the screw.
b. Connect the connector and ash receptacle light, and install the armrest base panel assembly.

27. INSTALL NO. 2 DOOR INSIDE HANDLE BEZEL

For Power Window Initialization/Reset Programming and Relearning