Rear Door: Service and Repair
OVERHAULHINT:
- The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
- On the RH side, use the same procedures as on the LH side.
1. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH
a. Using a screwdriver, disengage the 3 claws.
HINT: Tape the screwdriver tip before use.
b. Remove the inside handle bezel.
2. REMOVE REAR ARMREST ASSY LH
a. Disengage the 4 claws, remove the armrest assy.
HINT: Tape the screwdriver tip before use.
3. REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH
a. Remove the cushion rubbers.
b. Remove the 2 screws.
c. Using a clip remover, disengage the 12 clips, remove the 12 clips.
d. Remove the trim board upward.
HINT: In order to prevent the door from being damaged, cover the parts indicated by arrow marks in the illustration with tape.
e. Disconnect the 2 cables from the inside handle.
f. Remove the trim board.
g. Remove the inner weatherstrip.
4. REMOVE REAR DOOR SERVICE HOLE COVER LH
NOTE: Remove the remaining tape on the door side.
5. REMOVE REAR SPEAKER ASSY
6. REMOVE REAR DOOR WINDOW FRAME MOULDING FRONT LH
7. REMOVE REAR DOOR GLASS WEATHERSTRIP OUTER
8. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH
HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched
a. Open the door glass until the bolts appear in the service hole.
b. Remove the door glass from the glass bracket and lower the door glass into the door panel.
NOTE: Do not damage the door glass.
HINT: Position the door glass toward the front as much as possible.
c. Remove the rear door glass run.
d. Remove the 2 bolts, screw and the division bar
e. Rotate the division bar by 900 and pull it upward as shown in the illustration.
9. REMOVE REAR DOOR QUARTER WINDOW GLASS LH
a. Remove the quarter glass, as shown in the illustration.
NOTE: Do not damage the glass.
b. Remove the quarter window weatherstrip from the glass.
10. REMOVE REAR DOOR GLASS SUB-ASSY LH
a. Carefully pull up the glass out of the panel.
HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched.
11. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY LH
a. Disconnect the window regulator connector.
b. Remove the 4 bolts and window regulator.
NOTE: When the bolts are removed, the rear door window regulator might drop and be deformed.
HINT: Remove the window regulator through the service hole.
12. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH
a. Place matchmarks on the window regulator motor gear and regulator gear.
b. Using a torx driver (T25), remove the 3 screws and window regulator motor.
13. REMOVE REAR DOOR W/MOTOR LOCK ASSY LH
a. Disconnect the door lock connector.
b. Using a torx socket wrench (T30), remove the 3 screws and door lock.
HINT: Remove the door lock through the service hole.
c. 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 and remove the outside handle cover.
15. REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH
a. Pull and hold the release plate of the outside handle frame, as shown in the illustration.
b. Pushing and pulling the outside handle in the arrow mark direction as shown in the illustration, remove the outside handle.
NOTE: If the release plate is not pulled and held when removing the outside handle, the release plate will interfere with the outside handle and it will damage the release plate.
c. Remove the 2 outside handle pad front and rear.
16. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
a. Using a torx socket wrench (T30), loosen the screw.
b. Slide the outside handle frame from to remove it.
HINT: Remove the outside handle frame through the service hole.
17. REMOVE REAR DOOR CHECK ASSY LH
a. Remove the 2 nuts, bolt and door check.
HINT: Remove the door check through the service hole
18. REMOVE FRONT DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clip, remove the weatherstrip.
HINT: If the clips are damaged, exchange them for new clips.
19. INSTALL REAR DOOR CHECK ASSY LH
a. Apply MP grease to the sliding part of the door check.
b. Install the door check to the door panel with the 2 nuts.
Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf)
c. Apply adhesive to 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 N.m (306 kgf.cm, 22 ft.lbf)
HINT: Install the door check so that rivet head is up.
20. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH
a. Using a torx socket wrench (T30), install the handle frame with the screw.
Torque: 7.0 N.m (56 kgf.cm, 49 in.lbf)
21. INSTALL REAR DOOR OUTSIDE HANDLE ASSY LH
a. Install the outside handle pad front and rear.
b. Pull and hold the release plate of the outside handle frame, as shown in the illustration.
c. Pushing the outside handle in the arrow mark direction as shown in the illustration, install the outside handle.
NOTE: If the release plate is not pulled and held when installing the outside handle, the release plate will interfere with the outside handle and it will damage the release plate.
22. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), install the outside handle cover with the screw.
Torque: 7.0 N.m (56 kgf.cm, 49 in.lbf)
23. INSTALL REAR DOOR W/MOTOR LOCK ASSY LH
a. Apply MP grease to the sliding and rotating parts of the door lock.
b. Install a new door lock wire harness packing.
NOTE:
- If reusing the door lock that is removed, replace the packing in the connecting part with a new one.
- Be careful that no grease and dirt will stick to the packing surface in the connecting part.
- Reusing the packing that is removed or using a damaged packing will cause water to penetrate through the connecting part, and it will result in a malfunction of the door lock.
c. Engage the lock with door motor with the release plate of the outside handle, and then set it to the door panel.
NOTE: Make sure that the release plate of the outside handle frame is securely engaged with the lock.
d. Apply adhesive to 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 N.m (51 kgf.cm, 42 in.lbf)
f. Connect the door lock connector
24. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH
a. Using a torx driver (T25), install the door window regulator motor with the 3 screws.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
25. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSY LH
a. Apply MP grease to the sliding and rotating parts of the window regulator.
NOTE: Do not apply grease to the spring of the window regulator.
b. Install the door window regulator with the 4 bolts.
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
NOTE: Be careful not to drop and deform the rear door window regulator.
c. Connect the window regulator connector.
26. INSTALL REAR DOOR GLASS SUB-ASSY LH
NOTE: Be careful not to drop and deform the front door window regulator.
a. Insert the rear door glass into the door panel.
HINT:
- Insert a shop rag inside the door panel to prevent the door glass from being scratched.
- Position the door glass toward the front as much as possible.
27. INSTALL REAR DOOR QUARTER WINDOW GLASS LH
a. Install the quarter window weatherstrip to the door glass.
NOTE: Do not damage the glass.
b. Install the door quarter window glass as shown in the illustration.
28. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH
a. Insert the division bar to the door panel, then rotate it by 90° as shown in the illustration.
b. Mount the door glass to the window regulator.
c. Tighten the division bar with the 2 bolts and screw.
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
d. Install the glass run.
HINT: When the installation point of the door glass does not match, adjust the regulator position in manual operation.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Repeat UP and DOWN operation several times in manual operation.
29. INSTALL REAR DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door, as shown in the illustration.
Adhesive:
Part No. 08850-00065, Butyl Tape Set or equivalent
b. Install the service hole cover.
Dimension:
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 condition.