Rear Door: Service and Repair

Rear Door Part 1:

Rear Door Part 2:

OVERHAUL

HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- Use the same procedures for the RH side and LH side.




1. REMOVE DOOR PULL HANDLE
a. Remove the screw and handle upward.




2. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR
a. Using a screwdriver, disengage the 2 claws labelled A in the illustration. Remove the armrest base panel upper together with the switch.

HINT: Tape the screwdriver tip before use.

b. Disengage the 2 claws labelled B in the illustration. Remove the switch.

HINT: Tape the screwdriver tip before use.





3. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the screw as in the illustration.
b. Using a clip remover, disengage the 7 clips.
c. Remove the trim board upward.

HINT: In order to prevent the door panel from being damaged, use protective tape to cover the areas indicated by the arrow marks in the illustration.

d. Using a screwdriver, disengage the claws, and remove the weatherstrip inner.

HINT: Tape the screwdriver tip before use.




4. REMOVE REAR DOOR INSIDE HANDLE SUB-ASSEMBLY LH
a. Using a screwdriver, disengage claw A indicated in the illustration.

HINT: Tape the screwdriver tip before use.

b. Move the inside handle in the direction indicated by the arrow mark in the illustration.
c. Disconnect the rod from the inside handle.

5. REMOVE REAR DOOR SERVICE HOLE COVER LH




a. Remove the 2 screws and bracket.




b. Remove the service hole cover.

NOTE: Remove the remaining tape on the door side.

6. REMOVE REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH




7. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH

HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched.

NOTE: Be careful not to damage the glass.

a. Lower the glass as far as it can lower.
b. Remove the glass run.
c. Remove the 2 bolts and screw.




d. Rotating the division bar, remove it, as shown in the illustration.




8. REMOVE REAR DOOR QUARTER WINDOW GLASS LH
a. Remove the window glass in the direction indicated by the white arrow mark in the illustration.

NOTE: Be careful not to damage the glass.

b. Remove the quarter window glass weatherstrip.

9. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH
a. Carefully pull up the door glass up out of the door panel.

HINT: Insert a shop rag inside the door panel to prevent the door glass from being scratched.




10. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Remove the 4 bolts and window regulator.

NOTE: Be careful when removing the bolts as the window regulator may fall and become damaged.

HINT: Remove the window regulator through the service hole.




11. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Using a torx driver (T25), remove the 3 screws and motor.

12. REMOVE REAR DOOR LOCK ASSEMBLY LH




a. Disconnect the snap and remote control rod No. 2 in the direction indicated by the white arrow marks in the illustration.




b. Twist the knob and remove it, as shown in the illustration.
c. Using a screwdriver, disengage the 2 claws and remove the guide.

HINT: Tape the screwdriver tip before use.




d. Using a screwdriver, disengage the 4 claws and remove the bellcrank with the remote control rod and remote control rod No. 2.

HINT: Tape the screwdriver tip before use.

e. Remove the remote control rod and remote control rod No. 2.




f. Using a torx socket wrench (T30), remove the 3 screws and door lock.

NOTE: Be careful when removing the bolts as the door lock may fall and become damaged.

HINT: Remove the door lock through the service hole.




g. Remove the 2 screws and the actuator.

13. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH




a. Remove the bolt and nut, and outside panel hole seal.




b. Remove the bolt and handle.

NOTE: Be careful when removing the bolt as the outside handle may fall and become damaged.




14. REMOVE REAR DOOR CHECK ASSEMBLY LH
a. Remove the 3 bolts and check.

HINT: Remove the check through the service hole.

15. REMOVE REAR DOOR WEATHERSTRIP LH
a. Using a clip remover, disengage the clip and remove the weatherstrip.

HINT: If clips are damaged during removal, replace them.




16. INSTALL REAR DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding areas of the check.
b. Install the check to the door panel with the 2 bolts.
Torque: 5.5 Nm (56 kgf.cm, 49 in.lbf)

HINT: Install the door check so that the rivet head is facing up.

c. Apply adhesive to the threads of the bolt.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

d. Install the check to the body panel with the bolt.

Torque: 30 Nm (306 kgf.cm, 22 ft.lbf)

17. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH




a. Install the handle with the bolt.

Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)




b. Install the outside panel hole seal with the bolt and nut.

Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)

18. INSTALL REAR DOOR LOCK ASSEMBLY LH




a. Install the actuator with the 2 screws.




b. Apply MP grease to the sliding and rotating areas of the door lock.




c. Apply adhesive to the threads of the 3 screws.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

d. Using a torx socket wrench (T30), install the door lock with the 3 screws.

Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)

e. Connect the door lock connector.




f. Install the bellcrank, remote control rod and remote control rod No. 2.




g. Install the guide.
h. Attach the knob in the direction indicated by the white arrow marks in the illustration.

HINT: After attaching the knob, rotate it 90 degrees in the direction by the arrow marks in the illustration.




i. Connect the remote control rod No. 2 in the direction indicated by the arrow marks in the illustration.




19. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY RH
a. Using a torx driver (T25), install the motor with the 3 screws.

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

20. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH




a. Apply MP grease to the sliding and rotating areas of the window regulator.

NOTE: Do not apply grease to the spring of the window regulator.




b. Install the window regulator with the 4 bolts.

Torque: 8.0 Nm (82 kgf.cm, 71 in.lbf)

c. Connect the window regulator connector.

NOTE: Be careful not to drop the window regulator as it may become damaged.

21. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH

NOTE: Be careful not to damage the glass.

a. Install the door glass into the door panel.

HINT: Insert a shop rag inside the door panel to prevent the door glass from being scratched.




22. INSTALL REAR DOOR QUARTER WINDOW GLASS LH
a. Install the quarter window weatherstrip on the glass.

NOTE: Be careful not to damage the glass.

b. Install the quarter window glass in the direction indicated by the white arrow mark in the illustration.
c. Mount the door glass to the window regulator along the glass run.

23. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH




a. Insert the division bar into the door panel and then rotate it by 90°, as shown in the illustration.




b. Install the division bar with the 2 bolts and screw.

Torque: 5.0 Nm (51 kgf.cm, 44 in.lbf)

c. Install the glass run.
d. Check operation of the power window.
1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Use the UP and DOWN function several times.
If the result is not as specified, check the power window control switch.


24. INSTALL REAR DOOR SERVICE HOLE COVER LH




a. Apply butyl tape to the door, as shown in the illustration.
b. Install a new service hole cover.

HINT:
- When installing the service hole cover, pull out the links and connectors through the service hole cover.
- There should be no wrinkles or folds after attaching the service hole cover.
- After attaching the service hole cover, check the sealing quality.




c. Install the bracket with the 2 bolts.