Procedures

1. Verify that the rear door water liner is the source of the waterleak by running an unrestricted flow of water along the rear door glass, on top of the outer sealing strip.





2. Inspect for water trails or drops at lower perimeter of inner door trim panel.

^ If water trails are present at lower perimeter of inner door trim panel, proceed to next step.

^ If water trails are not present at lower perimeter of inner door trim panel, refer to "Waterleaks" in the "General Information" section of the "1996 Body/Repair Service Manual."





3. Remove fasteners from center of inside door handle assembly. Slide door handle assembly forward, while pulling outward from the trim panel. Using a thin screwdriver, disengage lock and latch rod from retainers.





4. On vehicles with manual windows, disengage manual window handle regulator clip, using a window handle tool. Remove window handle from vehicle.

5. Open access cover at rear of door trim panel and remove door trim panel fastener.

6. Remove door trim panel fasteners at pull cup location.

7. Pull up on door trim panel assembly to disengage trim panel to door structure attaching hooks and remove door trim panel.





8. Remove energy absorbing foam material from door structure.





9. Carefully peel up the lower edge of the rear door water liner.

10. Using the edge of the water liner as a guide, install a continuous length of butyl rubber such as Kent Industries Versatape VT-B 20290 or equivalent beneath the outer edge of the lower half of the water liner.

11. Install removed edges of water liner on top of the butyl rubber. Make sure there are no wrinkles in water liner.

12. Apply light pressure to the water liner edges with either a roller or similar tool for the entire bonded surface to ensure a water tight seal.

IMPORTANT:
Wrinkles in the lower half of the water liner bond joint will result in a waterleak.





13. Remove upper (white liner) cone array.

14. Install 3M(R) Electrical Moisture Sealant Patches (P/N 06149) or equivalent over the 25 x 25 mm upper rear trim panel attachment hole and the 25 x 30 mm access hole located directly above it in the inner door structure. (Holes are located in the inner door where the upper [white liner] cone array was removed from.)





15. If the vehicle was built before and includes VIN TZ243340, remove the upper rear attachment hook using a utility knife or fine saw blade.

On vehicles built after and including VIN TZ243341, the attachment hook is no longer present.

16. Water test vehicle to verify repair.





CAUTION:
IF ENERGY ABSORBING FOAM IS REMOVED FROM DOOR, IT MUST BE REPLACED WITH A NEW PART. IF OMITTED FROM THE DOOR, THE VEHICLE WILL NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS (FMVSS), SUBJECTING THE RETAILER TO POSSIBLE CIVIL PENALTIES FOR MAKING THE VEHICLE INOPERATIVE TO THE FMVSS, AND INCREASING THE RISK OF INJURY TO THE VEHICLE OCCUPANTS.

17. Remove tape backing from new energy absorbing foam and install to door structure.





18. Position door trim panel to door structure at attaching hooks. Lock in door trim panel by pushing downward on door trim panel.

19. Install door trim panel fasteners at pull cup and at rear of door trim panel. Close access cover.

20. With window closed, install door handle onto vehicle with handle pointed in a forward and slightly upward position.

21. Position door handle assembly in trim panel. Tip handle outward at top. Using a thin hook style tool, lift latch and lock rods in trim panel and slide rearward to engage tabs.

22. Install screw in handle.





23. On vehicles with manual windows, install manual window regulator handle clip onto handle.