Rear Door: Service and Repair

Rear Door:

OVERHAUL

HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- Use the same procedures for the RH side and LH side.




1. REMOVE REAR DOOR REAR GUIDE BRACKET GARNISH LH
a. Using a heat light, heat the moulding.
Heating temperature: 20 to 30°C (68 to 86°F)

NOTE: Do not heat the moulding excessively.

b. Using a screwdriver, disengage the tape.

NOTE:
- If planning for use the moulding, take care not to damage it.
- Be careful not to damage the body.

HINT: Tape the screwdriver tip before use.

c. Using a screwdriver, disengage the 3 clips and 2 claws, and remove the garnish.

HINT: Tape the screwdriver tip before use.




2. REMOVE REAR DOOR ARMREST BASE PANEL UPPER LH
a. Using a screwdriver, disengage the 8 claws and clip, and remove the armrest base panel together with the switch.

HINT: Tape the screwdriver tip before use.

b. Disconnect the switch connector.
c. Disengage the 2 claws and remove the switch from the armrest base panel upper.




3. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the screw as shown in the illustration.
b. Using a clip remover, remove the 7 clips.
c. Remove the trim board upward.

HINT: In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration.

d. Using the screwdriver, disengage the claws and remove the weatherstrip inner.

HINT: Tape the screwdriver tip before use.




4. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH
a. Using a screwdriver, disengage claw A as shown in the illustration.

HINT: Tape the screwdriver tip before use.

b. Move the inside handle in the direction indicated by the arrow mark in the illustration.
c. Disconnect the 2 cables from the inside handle.

5. REMOVE REAR DOOR SERVICE HOLE COVER LH




a. Remove the 2 bolts and bracket.




b. Disconnect the 2 connectors.
c. Using a screwdriver, remove the clip indicted by the arrow mark and wire.

HINT: Tape the screwdriver tip before use.

d. Remove the service hole cover.

NOTE: Remove the remaining tape on the door side.

6. REMOVE REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH
7. REMOVE REAR DOOR WINDOW FRAME MOULDING REAR LH
8. REMOVE REAR SPEAKER ASSEMBLY




a. Using a drill of less than dia 4 mm (0.16 in.), drill out the heads of the 3 rivets and remove the speaker.

NOTE:
- Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
- Be careful as the cut rivet will be hot.

b. Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
c. Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the door.




9. REMOVE REAR DOOR WINDOW FRAME SUB-ASSEMBLY REAR LOWER LH
a. Lower the glass as it lower.
b. Remove the glass run.
c. Remove the bolt, nut and frame.




10. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH
a. Remove the glass from the regulator.

NOTE: Be careful not to damage the glass.




11. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Loosen bolt A as shown in the in the illustration.
c. Remove the 3 bolts and window regulator.

NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.

HINT: Remove the window regulator through the service hole.

d. Remove bolt A from the window regulator.




12. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx driver (T25), remove the 3 screws and motor.




13. REMOVE REAR DOOR W/MOTOR LOCK ASSEMBLY LH
a. Using a torx socket wrench (T30), remove the 3 screws and door lock.

NOTE: Be careful when removing the bolts as the door lock may fall and become damaged.

HINT: Remove the door lock through the service hole.

b. Remove the door lock wire harness packing.

14. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), loosen the screw.
b. Remove the cover.

HINT: Remove the cover through the service hole.

15. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH




a. Pull and hold the release plate of the handle frame as shown in the illustration.




b. Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.

NOTE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.

c. Remove the outside handle pad front and rear.

16. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH




a. Using a torx socket wrench (T30), loosen the screw and remove the frame.




b. Using pliers, remove the clip and handle frame, as shown in the illustration.

NOTE: Be sure to remove the outside handle frame together with the clip, because the clip will be damaged if the clip remain attached to the door panel.

HINT: Remove the handle frame through the service hole.




17. REMOVE REAR DOOR CHECK ASSEMBLY LH
a. Remove the 3 bolts and the door check.

HINT: Remove the door check through the service hole.

b. Using pliers, remove the clip and handle frame, as shown in the illustration.

NOTE: Be sure to remove the outside handle frame together with the clip, because the clip will be damaged if the clip remain attached to the door panel.

HINT: Remove the handle frame through the service hole.

18. REMOVE REAR DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clips and remove the weatherstrip.

HINT: If clips are damaged during removal, replace them.




19. INSTALL REAR DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding areas of the door check.
b. Install the door check to the door panel with the 2 bolts.

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

c. Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

d. Install the door check to the body panel with the bolt.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)




20. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Apply MP grease to the sliding areas of the frame.
b. Using a torx socket wrench (T30), install the handle frame with the screw.

Torque: 4.0 Nm (41 kgf.cm, 35 in.lbf)

21. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH




a. Install the outside handle pad front and rear.
b. Pull and hold the release plate of the frame as shown in the illustration.




c. Install the handle by pushing it in the direction indicated by the white arrow marks in the illustration.

NOTE: If the release plate is not pulled and held when installing the handle, the release plate will interfere with the handle and become damaged.

22. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), install the outside handle cover with the screw.

Torque: 4.0 Nm (41 kgf.cm, 35 in.lbf)

23. INSTALL REAR DOOR W/MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the door lock.
b. Install a new door lock wire harness packing.

NOTE:
- When reinstalling a door lock, always use new packing.
- Do not allow grease or dirt to contaminate the gap between the door panel and packing.
- Old packing or damaged packing cannot effectively protect against water. Water will damage the door lock.

c. Engage the door lock with the release plate of the handle, and then set it to the door panel.

NOTE: Make sure that the release plate of the frame is securely engaged with the door lock.




d. Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

e. Using a torx socket wrench (T30), install the door lock with the 3 screws.

Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)

f. Connect the door lock connector.




24. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
a. Using a torx driver (T25), install the motor with the 3 screws.

Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf)

25. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH




a. Apply MP grease to the sliding and rotating areas of the window regulator.

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




b. Loosely screw bolt A onto the window regulator.
c. Insert the window regulator into the door panel. Use bolt A to hang the window regulator on the door panel.
d. Install the window regulator with the 3 bolts and bolt A.

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

e. Connect the window regulator connector.

NOTE: Be careful not to drop the window regulator as it may become damaged.

26. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH

NOTE: Be careful to damage the door glass.

a. Install the door glass in the regulator.

HINT: Insert a shop rag inside the door panel to prevent the door glass from being scratched.




27. INSTALL REAR DOOR WINDOW FRAME SUB-ASSEMBLY REAR LOWER LH
a. Install the frame with the bolt and nut.

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




28. INSTALL REAR SPEAKER ASSEMBLY
a. Using a hand riveter or an air riveter, install the speaker.

NOTE:




- Do not operate the riveter at an angle as this will damage it and bend the mandrel.




- Do not tilt the riveter when installing the rivet as the speaker will not be tightened firmly.




- Install the rivet while attaching the speaker to ensure that it is tightened firmly.

b. Connect the speaker connector.




29. INSTALL REAR DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door, as shown in the illustration.
b. Install the service hole cover.

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, check the sealing quality.

c. Connect the 2 connectors and install the wire.
d. Install the bracket with the 2 bolts.




30. INSTALL REAR DOOR REAR GUIDE BRACKET GARNISH LH
a. Using a shop rag, remove the tape from the garnish.
b. Clean the contact surface of the door panel with shop rag saturated with white gasoline.
c. Clean the outer circumference of the garnish with white gasoline.




d. Using a heat light, heat the garnish.

NOTE: Do not heat the garnish excessively.




e. Apply new double-sided tape to the garnish, as shown in the illustration.




f. Using a heat light, heat the door panel and garnish.

NOTE: Do not heat the door panel and garnish excessively.

g. Remove the peeling paper from the moulding face.

HINT: Be careful that dirt or foreign objects do not stick to the adhesive when removing the peeling paper.

h. Install the garnish.

NOTE: Use steady pressure with your thumbs on the garnish, not excessive force.