Disassembly and Reassembly

REAR DOOR COMPONENTS

REAR DOOR DISASSEMBLY





1. REMOVE DOOR INSIDE HANDLE BEZEL
(a) Using a screwdriver, pry out the bezel.
(b) Pull the bezel backward to remove it.

HINT: Tape the screwdriver tip before use.

2. REMOVE DOOR TRIM
(a) Remove the armrest cover and screw.
(b) Remove the 3 clips.
(c) Insert a screwdriver between the panel and trim to remove the clips.
(d) Pull the trim upward to remove it.
(e) Disconnect the connector.
(f) Remove the 3 screws and armrest base panel.

3. REMOVE THESE PARTS:
(a) Door belt moulding
(b) Door weatherstrip
(c) Rear door outside moulding





4. REMOVE DOOR INSIDE HANDLE
(a) Remove the 3 screws.
(b) Disconnect the 2 links from the handle.





5. REMOVE SERVICE HOLE COVER

ASSEMBLY HINT: Bring out the links through the service hole cover.





6. REMOVE REAR DOOR UPPER STOP
Remove the 2 bolts and stops.

7. REMOVE REAR DOOR SUPPORT
Remove the 2 bolts and support.





8. REMOVE DOOR GLASS
(a) Remove the 2 glass mounting bolts.
(b) Remove the door glass by pulling it upward.

ASSEMBLY HINT: Insert a shop rag inside the panel to prevent scratching the glass.





9. REMOVE DOOR INSIDE PANEL PLATE
Remove the bolt and plate.

ASSEMBLY HINT: Tighten the bolt after door glass adjustment.

10. REMOVE WINDOW REGULATOR





(a) Remove the 8 nuts and regulator.

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

(b) Disconnect the connector.





ASSEMBLY HINT: Apply MP grease to the sliding surface and gears of the window regulator.

ASSEMBLY NOTICE: Do not apply MP grease to the spring of the window regulator.





11. REMOVE THESE PARTS:
(a) Guide upper plate
(b) Window rear guide
(c) Child protector lock lever knob

12. REMOVE OPENING CONTROL LINK AND INSIDE LOCKING LINK
(a) Remove the clip and protecting cover.
(b) Disconnect the 2 links from the door lock and remove them.





13. REMOVE DOOR LOCK
(a) Remove the 3 screws.

Torque: 5.4 N.m (55 kgf.cm, 48 In.Ibf)

(b) Remove the bolt.
(c) Disconnect the connector.
(d) Remove the door lock through the service hole.





ASSEMBLY HINT: Apply adhesive to the 3 screws.

Part No.08833-00070, THREE BOND 1324 or equivalent.

14. REMOVE OUTSIDE HANDLE

15. REMOVE DOOR INSIDE PANEL FRAME





ADJUST REAR DOOR GLASS
(a) Adjust lateral position of upper part of the door glass.
- Remove boll (A) and remove upper plate.
- Loosen 2 nuts (B).
- Loosen 2 nuts (C). then adjust the stud bolts using a hexagon wrench.
(b) Adjust the front/ rear position of the door glass.
- Loosen the 2 bolts (D), then adjust the door glass.
(c) Adjust the inclination of the rear end of the door glass.
- Loosen the 2 bolts (D).
(d) Adjust the glass in the vertical direction.
- Loosen the 2 bolts (B) and adjust the upper stop per vertically.
(e) Tighten the 2 nuts (B) until they touch the panel.
(f) Install the upper plate with the bolt.





(g) After adjustment is done, check the following items:
- When you close the door with the glass fully closed, the A-A, B-B sections are in the same condition as shown in the illustration.
- When you push the glass firmly from inside, the glass stops at the roof drip moulding and does not move.
- When you close the door with the glass fully closed, the glass is not caught in the outside lip of the weatherstrip and does not touch to the roof drip moulding.
- With the door closed, the glass moves smoothly.
- The upper edge of the glass cannot be seen from outside of the vehicle (edge touching roof side rail weatherstrip).
- When the glass is being raised, the glass and roof side rail weatherstrip are parallel, and the front and rear door window upper stops touch at the same time.





DOOR GLASS REPLACEMENT

1. REMOVE THESE PARTS:
(a) Stopper
(b) Stabilizers
(c) Bracket

2. REPLACE DOOR GLASS

WINDOW REGULATOR REPLACEMENT

1. REMOVE COVER PLATE





(a) Screw Type:
Remove the 2 screws and remove the cover plate.

HINT: The screws and cover plate can be used again.





Crimped Type:

HINT: Tape a screwdriver tip before use.
Using the screwdriver, pry up the cover plate tab and remove the cover plate.

NOTICE: Do not damage the motor housing.

HINT: The cover plate is not usable.





(b) Remove the drum and wire guide from motor.

NOTICE: Do not use a screwdriver etc. to help remove them.





2. INSTALL WINDOW REGULATOR

NOTICE:
- To prevent the drum and cable from coming off, do not tilt the drum, subject it to shocks or use force on it.
- If the cable comes off the drum, do not remind the cable and do not reuse it.
- After installing the window regulator, do not operate it by itself as some types of regulator do not have a stopper.

(a) Insert the window regulator drum into the motor housing.





Using Holding Tool A:
- Apply MP grease inside the motor housing.





- With the holding tool installed, motor the holding tool with the motor housing.
- Push down on the wire guide and drum, and insert the drum into the motor housing.

NOTICE: If you can not insert the drum into the motor, slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.

- Apply MP grease to the side of the drum.





Using Holding Tool B:
- Apply MP grease inside the motor housing.





- With the holding tool installed, partially insert the drum into the motor housing.
- Remove the holding tool, and insert the drum into the motor housing.

NOTICE: If you can not insert the drum into the motor. slowly slide the bracket for installing the glass, and insert the drum while aligning the drive shaft of the motor with the drum.

- Apply MP grease to the side of the drum.





(b) Install the cover plate.

Screw Type:
Install the cover plate using the 2 screws.





Crimped Type:
Use motor pump pliers to crimp the tab of the cover plate.

NOTICE:
- Use a new cover plate. (Non-reusable part)
- Do not hit the cover plate with a hammer, etc.
- Do not damage the motor housing.

REAR DOOR ASSEMBLY
Assembly is in the reverse order of disassembly.