Rear Door: Service and Repair

DOOR

REMOVAL

1. Open rear door.
2. Mark location of hinge on door end frame. 3.Disengage clips holding wire harness connector and boot to hinge pillar.
4. Remove connector from hinge pillar.
5. Disengage clip attaching wire connector together on hinge pillar side of the connector.
6. Remove door wire harness from instrument panel harness.
7. Remove bolts attaching check strap to hinge pillar.
8. Support door on suitable lifting device.

Fig. 2:

9. Remove bolt and nut attaching lower hinge to door end frame (Fig. 2).
10. Steady door on lifting device and remove bolt and nut attaching upper hinge to door end frame.
11. Remove door from vehicle.

INSTALLATION

1. Place door in position on vehicle.
2. Engage door onto pin on upper door hinge.
3. Steady door on lifting device and install bolt and nut attaching upper hinge to door end frame. Tighten the hinge bolt and nut to 28 N.m (250 in.lbs.) torque. If the double ended stud is loosen or replaced tighten the stud to 14 N.m (120 in.lbs.) torque.
4. Install bolt and nut attaching lower hinge to door end frame.
5. Verify door alignment and operation.
6. Connect door wire harness to instrument panel wire harness.
7. Attach check strap.
8. Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps. If door needs to be aligned (damages or hinge replacement) and can not be achieved, may be necessary to remove the double ended stud and replaced it with a bolt. This may allow extra movement to achieve the proper alignment.