Rear Door: Service and Repair

DISASSEMBLY




1. REMOVE REAR DOOR INSIDE HANDLE BEZEL
a. Remove the screw.
b. Using a screwdriver with its tip taped, disengage the 2 claws A.
c. Pull out the the rear door inside handle bezel in the direction indicated by the arrow, disengage the claw B, and remove the rear door inside handle bezel.




2. REMOVE DOOR PULL HANDLE
a. Using a screw driver wrapped with the protective tape, disengage the 2 clips and remove the door pull handle.




3. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY
a. Remove the screw.
b. Disengage the 7 clips.
c. Disconnect the connector and pull up on the rear door trim board sub-assembly to remove it.




4. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY
a. Remove the bolt.
b. Disengage the 2 claws and separate the rear door inside handle sub-assembly.
c. Disconnect the 2 cables and remove the rear door inside handle sub-assembly.

5. REMOVE REAR SPEAKER




6. REMOVE REAR DOOR SERVICE HOLE COVER
a. Disconnect each connector and remove the rear door service hole cover.

HINT: Remove the remaining tape on the door side.

7. REMOVE REAR DOOR GLASS RUN
a. Connect the window regulator switch assembly.
b. Fully lower the door glass.
c. Remove the rear door glass run.




8. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY
a. Remove the 2 bolts, the screw and rear door window division bar sub-assembly.




9. REMOVE REAR DOOR QUARTER WINDOW GLASS
a. Pull out the direction indicated by the arrow, remove the rear door quarter window glass and rear door quarter window weatherstrip as a unit.

10. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP




11. REMOVE REAR DOOR GLASS SUB-ASSEMBLY
a. Remove the rear door glass sub-assembly as shown in the illustration.
b. Disconnect the window regulator switch assembly




12. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY
a. Disconnect the connector.
b. Loosen the temporary bolt.

NOTE: If the temporary bolt is removed, the rear door window regulator may fall and become deformed.

c. Remove the 3 bolts and the rear door window regulator sub-assembly and the power window regulator motor assembly rear as a unit.
d. Remove the temporary bolt from the regulator.




13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR
a. Using a "torx" driver (T25), remove the 3 screws and power window regulator motor assembly rear.




14. REMOVE REAR DOOR LOCK ASSEMBLY
a. Disconnect the connector.
b. Remove the bolt.
c. Using a "torx" socket wrench (T30), remove the 3 screws.
d. Slide the rear door lock assembly downward, pull out the link from the outside handle frame, and remove the rear door lock assembly and cables as a unit.
e. Remove the door wire harness packing.




15. REMOVE REAR DOOR OUTSIDE HANDLE COVER
a. Using a "torx" socket wrench (T30), loosen the screw.




b. Disengage the 2 claws and remove the rear door outside handle cover.




16. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY
a. Pull and hold the release plate of the outside handle frame as shown in the illustration.

NOTE: The release plate may interfere with the outside handle and may be damaged when removing the handle, unless the release plate of the outside handle frame is pulled and held.




b. Remove the rear door outside handle assembly as shown in the illustration.




17. REMOVE REAR DOOR OUTSIDE HANDLE PAD
a. Disengage the 2 claws and remove the rear door outside handle pad.




18. REMOVE REAR DOOR OUTSIDE HANDLE PAD REAR
a. Disengage the 2 claws and remove the rear door outside handle pad rear.




19. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Using a "torx" socket wrench (T30), remove the screw.




b. Disengage the 2 claws and remove the rear door outside handle frame sub-assembly.




20. REMOVE REAR DOOR CHECK ASSEMBLY
a. Remove the 3 bolts and rear door check assembly.




21. REMOVE REAR DOOR WEATHERSTRIP
a. Disengage the 19 clips and remove the rear door weatherstrip.

22. REMOVE REAR DOOR BELT MOULDING ASSEMBLY

REASSEMBLY

1. INSTALL REAR DOOR BELT MOULDING ASSEMBLY
2. INSTALL REAR DOOR WEATHERSTRIP




3. INSTALL REAR DOOR CHECK ASSEMBLY
a. Install the rear door check assembly with the 3 bolts.

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

Torque: body side 27 N.m (275 kgf.cm, 20 ft.lbf)

4. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Apply body grease to the sliding parts on the rear door outside handle frame sub-assembly.




b. Engage the 2 claws.




c. Using a "torx" socket wrench (T30), install the rear door outside handle frame sub-assembly.

Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf)

5. INSTALL REAR DOOR OUTSIDE HANDLE PAD REAR
6. INSTALL REAR DOOR OUTSIDE HANDLE PAD
7. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY




8. INSTALL REAR DOOR OUTSIDE HANDLE COVER
a. Engage the 2 claws.




b. Using a "torx" socket wrench (T30), install the rear door outside handle cover with the screw.

Torque: 4.0 N.m (41 kgf.cm, 36 in.lbf)

9. INSTALL REAR DOOR LOCK ASSEMBLY

NOTE:
- When reusing the removed rear door lock assembly, replace the door lock wire harness sealing on the connector with a new one.
- Do not adhere the grease or dust to the door lock wire harness sealing surface of the connector.
- Reusing the door lock wire harness sealing and/ or using damaged door lock wire harness sealing may cause water intrusion to the connection, and result in a malfunction on the rear door lock assembly.

a. Apply body grease to the sliding parts on the rear door lock assembly.




b. Insert the rear door lock assembly to the rear door outside handle release plate, and set to rear door panel.
c. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.
d. Using a "torx" socket wrench (T30), install the rear door lock assembly with the 3 screws.

Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf)

e. Install the bolt.

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

f. Connect the connector.

10. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY REAR

NOTE: The regulator arm must be below the intermediate position when installing the power window regulator motor.




a. Using a "torx" driver (T25), install the power window regulator motor assembly with the 3 screws.

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

HINT: The new rear window regulator adopts a self tapping method. The installation position of regulator will be threaded when the self-tapping screw is inserted.

11. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY
a. Apply body grease to the sliding parts on the rear door window regulator sub-assembly.




b. Install the temporary bolt to the rear door window regulator sub-assembly.

c. Tighten the 4 bolts and install the rear door window regulator sub-assembly.

Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)

d. Connect the connector.

12. INSTALL REAR DOOR GLASS SUB-ASSEMBLY
13. INSTALL REAR DOOR QUARTER WINDOW GLASS
14. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY
15. INSTALL REAR DOOR GLASS RUN




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

17. INSTALL REAR SPEAKER




18. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY
a. Connect the 2 cables.

b. Install the rear door inside handle sub-assembly with the bolt and the 2 claws.

Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)

19. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY
20. INSTALL DOOR PULL HANDLE

21. INSTALL REAR DOOR INSIDE HANDLE BEZEL
a. Install the rear door inside handle bezel with the screw and the 3 claws.

Torque: 3.5 N.m (36 kgf.cm, 31 in.lbf)

22. POWER WINDOW CONTROL SYSTEM INITIALIZATION Programming and Relearning