Rear End Door Assembly Removal and Installation

Rear End Door Assembly Removal and Installation

Rear End Door Assembly Components

Removal

1) Remove rear end door trims (1).
2) Remove spare tire.
3) Disconnect rear end door harness coupler (2) and washer hose (3).
4) Remove rear end door balancer (4).
5) Remove door hinge bolts (5) and remove rear end door assembly (6).






WARNING:
Improperly handling or disposing of the rear end door balancers can result in personal injury.
- Never try to disassemble a balancer (1). The gas inside the balancer 's cylinder can cause personal injury.
- Before discarding any rear end door balancer, a hole must be drilled in the cylinder part using a 2 to 3 mm (0.08 to 0.12 in.) drill (2) to release the inside gas. Be sure to wear goggles when drilling the hole because metal chips produced by the drilling will be propelled by the gas discharged through the hole and may injure your eyes.





NOTE:
Failure to take proper precautions when handling the removed rear end door balancers (dampers) can cause damage to balancers or can cause them not to work properly after reinstallation.
- Do not scratch the exposed surface of the piston rod. Also, do not allow paint or oil to touch the surface of the piston rod.
- Do not turn the piston rod with the balancer fully extended.

Installation

Reverse removal procedure noting the following.

- Tighten rear end door hinge bolts and balancer nut to specified torque referring to Rear End Door Assembly Components Rear End Door Assembly Components
- Secure wiring harness (1).





- Adjust door latch striker position by referring to Removal and Installation Rear End Door Lock Assembly Removal and Installation.
- Adjust door cushion so that door contacts body when closed.
- Apply sealant to contact face "A" of door hinge (1) and apply grease to rotating part "B" of hinge (1).

"A" Sealant: 99000-31110 (SUZUKI Bond No.1215)

"B" Grease: 99000-25010 (SUZUKI Super Grease A)