Rear Door: Service and Repair
4 DOORRemoval
1. Disconnect negative battery cable.
2. Remove door trim. Refer to "Trim".
3. Remove one screw on pull handle bracket.
4. Remove pull handle bracket.
5. Peel off plastic door screen carefully by pulling it away gradually from door frame.
6. Remove glass run channel.
7. Remove window glass:
a. Reconnect window operating switch.
b. Connect negative battery cable.
c. Turn ignition "ON" and position window glass about halfway.
d. Turn ignition "OFF"
e. Disconnect negative battery cable.
f. Remove glass run channel.
g. Remove two glass retaining bolts on regulator assembly.
h. Remove door glass carefully. Hold glass from both its inner and outer surfaces. While tilting it toward hinge side of door, pull it out from outside door frame.
8. Remove glass guide.
a. Remove one bolt and one nut on glass guide.
b. Remove glass guide from access hole.
9. Remove three screws on door lock assembly.
10. Remove door lock assembly from access hole.
11. Remove two nuts on outside door handle from access hole.
12. Remove outside door handle.
13. Disconnect window regulator motor connector.
14. Remove six nuts on window regulator assembly.
15. Remove window regulator assembly from access hole.
16. Remove wire harness from access hole towards hinge side of door.
17. Remove outside molding around window opening.
18. Remove door checker assembly.
a. Remove one bolt on checker pin assembly.
b. Remove checker pin assembly from access hole.
19. Remove door:
a. Remove bolts on both hinges.
b. Remove door.
Installation
1. Install door.
a. Position door on vehicle properly.
b. Install bolts on both hinges.
Tighten door hinge bolts to 13 - 22 lb.ft (18 - 30 N.m, 1.8 - 3.0 kg.m)
2. Install door checker pin assembly.
a. Position checker pin assembly through access hole.
b. Install one bolt.
Tighten one bolt to 16 - 20 lb.ft (22 - 28 N.m, 2.2 - 2.8 kg.m)
3. Install outside molding around window opening.
4. Position wire harness from hinge side of door.
5. Position regulator assembly.
6. Install six nuts on window regulator assembly.
7. Position outside door handle.
8. Install two nuts on outside door handle from access hole.
9. Connect outside door handle rod of door lock assembly to outside door handle.
10. Position door lock assembly from access hole.
11. Install three screws on door lock assembly.
12. Install glass guide.
a. Position glass guide as originally positioned through access hole.
b. Install one bolt and one nut.
Tighten bolt and nut to 78 - 113 lb.in (9 - 13 N.m, 90 - 130 kg.cm)
13. Install window glass.
a. Position glass carefully:
Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, push it in from outside door frame and place on glass mounting bracket of regulator assembly.
b. Loosely install two glass mounting bolts on window regulator assembly.
NOTE: Make sure that glass edges are properly fitted into window edges.
c. Reconnect window operating switch.
d. Connect negative battery cable.
e. Turn "ON" ignition and move glass up and down to ensure proper function.
f. Make adjustments as necessary.
g. Turn "OFF" ignition.
h. Disconnect negative battery cable.
i. Tighten two glass mounting bolts on power window regulator assembly.
j. Connect negative battery cable.
k. Turn "ON" ignition.
l. Position window all way down.
m. Turn "OFF" ignition.
n. Disconnect negative battery cable.
o. Remove power switch.
14. Install glass run channel.
Use soap and water for lubrication.
15. Install plastic screen on door frame, make sure to pull out door lock knob rod and inside door handle rod of door lock assembly from plastic screen.
16. Install pull handle bracket.
a. Position pull handle bracket.
b. Install one mounting screw.
17. Install trim. Refer to "Trim".
18. Connect negative battery cable.
5 DOOR
Removal
1. Remove inner glass weatherstrip.
2. Remove door trim. Refer to "Trim".
3. Remove one screw on pull handle bracket.
4. Remove inside door handle assembly.
a. Remove three screws from inside door handle.
b. Disconnect two control rods.
c. Remove inside door handle assembly.
5. Peel off plastic door screen carefully by pulling it away gradually from door frame.
6. Remove window glass:
a. Reconnect window operating switch.
b. Connect negative battery cable.
c. Turn on ignition and position window glass about halfway.
d. Turn off ignition.
e. Remove two glass retaining bolts on regulator assembly.
f. Remove door glass carefully. Hold glass from both its inner and outer surfaces. While tilting it toward hinge side of door, pull it out from outside door frame.
g. Disconnect negative battery cable.
7. Remove harness connector.
8. Remove two nuts on outside door handle from access hole.
9. Remove outside door handle.
10. Remove three screws on door lock assembly.
11. Remove door lock assembly from access hole.
12. Disconnect window regulator motor connector.
13. Remove six nuts on window regulator assembly.
14. Remove window regulator assembly from access hole.
15. Disconnect connector and its retaining clip from actuator.
16. Remove wire harness from access hole towards hinge side of door.
17. Remove run channel.
18. Remove outer glass weatherstrip.
19. Remove outside molding around window opening.
20. Remove door checker assembly.
a. Remove one bolt on checker pin assembly.
b. Remove checker pin assembly from access hole.
21. Remove dust weatherstrip.
22. Remove door:
a. Remove bolts on both hinges.
b. Remove door.
Installation
1. Install door.
a. Position door on vehicle properly.
b. Install bolts on both hinges.
Tighten door hinge bolts to 12 - 21 lb.ft (17 - 29 N.m, 1.7 - 3.0 kg.m)
2. Install dust weatherstrip.
3. Install door checker pin assembly.
a. Position checker pin assembly through access hole.
b. Install one bolt.
Tighten one bolt to 16 - 20 lb.ft (22 - 27 N.m, 2.2 - 2.8 kg.m)
4. Install outside molding around window opening.
5. Install outer glass weatherstrip.
6. Install channel.
7. Position wire harness from hinge side of door.
8. Connect actuator connector.
9. Position regulator assembly.
10. Install six nuts on window regulator assembly.
Tighten six nuts to 78 - 113 lb.in (9 - 13 N.m, 90 - 130 kg.cm)
11. Connect window regulator motor connector.
12. Position door lock assembly from access hole.
13. Install three screws on door lock assembly.
14. Position outside door handle.
15. Install two nuts on outside door handle from access hole.
Tighten two bolts to 78 - 113 lb.in (9 - 13 N.m, 90 - 130 kg.cm)
16. Connect outside door handle rod of door lock assembly to outside door handle.
17. Install glass guide.
a. Position glass guide as originally positioned through access hole.
b. Install one nut.
Tighten one bolt to 78 - 113 lb.in (9 - 13 N.m, 90 - 130 kg.cm)
18. Install glass piece carefully.
a. Use lubricant around window opening edges.
b. Hold glass from both its inner and outer surfaces. While tilting it towards hinge side of door, push it in from outside door frame and place on glass mounting bracket of regulator assembly.
Note: Make sure that glass edges are properly fitted into window edges.
19. Install two glass mounting bolts on window regulator.
20. Make glass adjustments as necessary.
21. Install plastic screen on door flame, make sure to pull out door lock knob rod and inside door handle rod of door lock assembly from plastic screen.
22. Install inside door handle.
a. Connect two control rods of door lock assembly.
b. Install three mounting screws
Tighten three screws to 26 - 35 lb.in (3 - 4 N.m, 30 - 40 kg.cm)
23. Install pull handle bracket.
a. Position pull handle bracket.
b. Install one retaining screw.
24. Connect harness connector.
25. Install trim. Refer to "Trim".
26. Connect negative battery cable.
27. Move window glass to maximum upper position.