Rear Door: Service and Repair

REAR DOOR

Rear Door:

DISASSEMBLY

1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG

a. Using a screwdriver wrapped with protective tape, disengage the 3 claws and remove the rear door inside handle bezel plug.

2. REMOVE REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY

a. Using a screwdriver wrapped with protective tape, disengage the 2 claws and 2 clips.
b. Disconnect the connector and remove the rear power window regulator switch assembly.

3. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY

a. Remove the 2 screws.
b. Using the clip remover, disengage the 8 clips.

c. Pull out the rear door trim board in the direction indicated by the arrow.
d. Remove the reference bosses from the rear door panel.
e. Raise the rear door trim board to disengage the 3 claws and remove the rear door trim board together with the rear door inner glass weatherstrip.

f. Disconnect the cables and each connector from the back side of the inside handle and the rear door trim board sub-assembly, remove the rear door trim board sub-assembly.
g. Remove the 2 rear door trim board retainers (green) from the rear door trim board.

4. REMOVE REAR NO. 2 SPEAKER ASSEMBLY
5. REMOVE REAR DOOR INNER GLASS WEATHERSTRIP

a. Disengage the 3 clips as shown in the illustration and remove the rear door inner glass weatherstrip from the rear door trim board.

6. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

a. Remove the 3 screws and bracket.

b. Remove the 5 screws and rear door inside handle sub-assembly.

7. REMOVE REAR DOOR TRIM COVER

a. Remove the screw.
b. Using a clip remover, detach the 5 clips and remove the rear door trim cover.

8. REMOVE REAR DOOR FRAME GARNISH

a. Using a screwdriver, remove the 2 clips and rear door frame garnish.

9. REMOVE REAR SPEAKER ASSEMBLY
10. REMOVE REAR NO. 3 SPEAKER ASSEMBLY (w/o Front Center Speaker)
11. REMOVE REAR DOOR SERVICE HOLE COVER

a. Disconnect the connector and 2 clamps.
b. Remove the rear door service hole cover.

HINT: Remove the remaining tape on the door side.

12. REMOVE REAR DOOR CHECK COVER

a. Remove the rear door check cover.

13. REMOVE REAR DOOR CHECK ASSEMBLY

a. Remove the bolt, 2 nuts, and the rear door check assembly.

14. REMOVE REAR DOOR WEATHERSTRIP

a. Using the clip remover, disengage the 23 clips and remove the rear door weatherstrip.

15. REMOVE REAR DOOR GLASS RUN

a. Remove the rear door glass run.

16. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

a. Remove the 2 bolts, the screw, and the rear door window division bar sub-assembly.

17. REMOVE REAR DOOR QUARTER WINDOW GLASS

a. Remove the rear door quarter window glass and the rear door quarter window weatherstrip as a unit as shown in the illustration.
b. Remove the rear door quarter window glass from the rear door quarter window weatherstrip.

18. REMOVE REAR DOOR GLASS SUB-ASSEMBLY

a. Remove the rear door glass sub-assembly from the rear door window regulator sub-assembly as shown in the illustration.

NOTICE: Do not damage the door glass.

19. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY

a. Disconnect the connector.
b. Loosen the temporary bolt.

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

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

20. REMOVE REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

a. Using a "torx" driver (T25), remove the 3 screws and the rear power window regulator motor assembly.

21. REMOVE REAR DOOR LOCK ASSEMBLY

a. Using a "torx" socket wrench (T30), remove the 3 screws.
b. Move the rear door lock assembly downward and pull the release plate out of the rear door outside handle frame.
c. Remove the door lock wiring harness sealing from the rear door lock assembly.

22. REMOVE REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

a. Using a screwdriver, disengage the claw.

HINT: Tape the screwdriver tip before use.

b. Remove the rear door lock remote control cable assembly.

23. REMOVE REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

a. Using a screwdriver, disengage the 3 claws.

HINT: Tape the screwdriver tip before use.

b. Remove the rear door inside locking cable assembly.

24. REMOVE REAR DOOR OUTSIDE HANDLE COVER

a. Using a "torx" socket wrench (T30), loosen the screw.

b. Pull and hold the release plate of the outside handle frame as shown in the illustration.

NOTICE: 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.

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

26. REMOVE REAR DOOR FRONT OUTSIDE HANDLE PAD

a. Disengage the 3 claws and remove the rear door front outside handle pad.

27. REMOVE REAR DOOR REAR OUTSIDE HANDLE PAD

a. Disengage the 2 claws and remove the rear door rear outside handle pad.

28. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

a. Using a "torx" socket wrench (T30), loosen the screw.

HINT: The screw cannot be removed because it is integrated into the rear door outside handle frame sub-assembly.

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

29. REMOVE REAR DOOR BELT MOULDING ASSEMBLY
30. REMOVE REAR DOOR FRONT WINDOW FRAME MOULDING
31. REMOVE REAR DOOR UPPER WINDOW FRAME MOULDING

REASSEMBLY

1. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING
2. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING
3. INSTALL REAR DOOR BELT MOULDING ASSEMBLY
4. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY
a. Apply MP grease to the sliding parts on the rear door outside handle frame sub-assembly.

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

5. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

a. Attach the 2 claws to install the rear door rear outside handle pad.

6. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

a. Attach the 3 claws to install the rear door front outside handle pad.

7. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY

a. Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.

NOTICE: If the bellcrank lever is not pulled and held when installing the outside handle, the bellcrank lever will interfere with the outside handle and it will damage the release plate.

b. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame. Next slide the rear door outside handle assembly to the front of the vehicle to install it.

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

8. INSTALL REAR DOOR OUTSIDE HANDLE COVER

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

9. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

a. Install the rear door inside locking cable assembly.

b. Engage the 3 claws.

10. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

a. Install the rear door lock remote control cable assembly.

b. Engage the claw.

11. INSTALL REAR DOOR LOCK ASSEMBLY

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

a. Apply MP grease to the sliding parts on the rear door lock assembly.
b. Install a new door lock wiring harness sealing to the rear door lock assembly.

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

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

f. Connect the connector.

12. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

NOTICE: 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 the regulator will be threaded when the self-tapping screw is inserted.

13. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY
a. Apply MP 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. Temporarily install the window regulator.
d. Tighten the 4 bolts in the order shown in the illustration to install the rear door window regulator.

Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf)

e. Connect the connector.

14. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

a. Slide the rear door glass sub-assembly to install it as shown in the illustration.

15. INSTALL REAR DOOR QUARTER WINDOW GLASS
a. Install the rear door quarter window glass to the rear door quarter weatherstrip.

b. Install the rear door quarter window glass together with the rear door quarter window glass weatherstrip in the direction indicated by the arrow in the illustration.

16. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY

a. Insert the rear door window division bar from up above and install it with the 2 bolts and screw.

17. INSTALL REAR DOOR GLASS RUN

a. Install the rear door glass run.

18. INSTALL REAR DOOR WEATHERSTRIP

a. Engage the 23 clips and install a new rear door weatherstrip.

19. INSTALL REAR DOOR CHECK ASSEMBLY

a. Install the rear door check assembly with the bolt and the 2 nuts.

Torque:
Bolt: 27 N.m (275 kgf.cm, 20 ft.lbf)
Nut: 8.0 N.m (82 kgf.cm, 71 in.lbf)

20. INSTALL REAR DOOR CHECK COVER

a. Install the rear door check cover.

21. INSTALL REAR DOOR SERVICE HOLE COVER
a. Apply butyl tape to the rear door panel.

b. Pass the rear door lock remote control cable, rear door inside locking cable and each connector through a new rear door service hole cover.
c. Install a new rear door service hole cover.

NOTICE: Securely install the rear door service hole cover avoiding wrinkles and air bubbles.

d. Connect the connector and clamp.

22. INSTALL REAR NO. 3 SPEAKER ASSEMBLY (w/o Front Center Speaker)
23. INSTALL REAR SPEAKER ASSEMBLY
24. INSTALL REAR DOOR FRAME GARNISH

a. Install the door frame garnish with the 2 clips.

25. INSTALL REAR DOOR TRIM COVER

a. Engage the 5 clips to install the rear door trim cover.
b. Install the screw.

26. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

a. Engage the 3 claws to install the rear door inner glass weatherstrip.

27. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

a. Install the rear door inside handle sub-assembly with the 5 screws.

b. Install the bracket with the 3 screws.

28. INSTALL REAR NO. 2 SPEAKER ASSEMBLY
29. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

a. Connect the rear door lock remote control cable and rear door inside locking cable to the rear inside handle.
b. Connect each connector.

c. Engage the rear door trim board with the 3 clips of the rear door inner glass weatherstrip.

d. Engage the 8 clips to install the rear door trim board to the rear door panel.
e. Install the 2 screws.

30. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY
a. Connect the connector.

b. Engage the 2 claws and 2 clips, and install the rear power window regulator switch assembly.

31. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

a. Engage the 3 claws to install the rear door inside handle bezel plug.

32. INITIALIZATION POWER WINDOW CONTROL SYSTEM [1][2]Programming and Relearning