Rear Door: Service and Repair

REAR DOOR

COMPONENTS

Rear Door:

DISASSEMBLY

HINT:
- Use the same procedure for the RH side and LH side.
- The procedures listed below are for the LH side.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE REAR DOOR REAR GUIDE BRACKET GARNISH LH
(a) Using a heat light, heat the moulding.
Standard heating temperature: 20 to 30°C (68 to 86°F)

NOTICE: Do not heat the moulding excessively.

NOTICE:
- If planning to reuse the moulding, take care not to damage it.
- Be careful not to damage the body.

(b) Using a screwdriver, detach the tape.

HINT: Tape the screwdriver tip before use.

(c) Using a screwdriver, detach the 3 clips and 2 claws, and remove the garnish.

HINT: Tape the screwdriver tip before use.

3. REMOVE REAR DOOR ARMREST BASE PANEL UPPER LH

(a) Remove the screw.
(b) Using a screwdriver, detach the 8 claws and clip, and remove the armrest base panel together with the switch.

HINT: Tape the screwdriver tip before use.

(c) Disconnect the switch connector.
(d) Detach the 2 claws and remove the switch from the armrest base panel upper.

4. REMOVE REAR DOOR TRIM BOARD SUBASSEMBLY LH

(a) Remove the screw shown in the illustration.
(b) Using a clip remover, remove 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, detach the claws and remove the weatherstrip inner.

HINT: Tape the screwdriver tip before use.

5. REMOVE REAR DOOR INSIDE HANDLE SUBASSEMBLY LH

(a) Using a screwdriver, disengage the claw.

HINT: Tape the screwdriver tip before use.

(b) Move the inside handle in the direction indicated by the arrow mark in the illustration. This will release the 2 claws and allow removal of the inside handle.
(c) Disconnect the 2 cables from the inside handle.

6. REMOVE REAR DOOR SERVICE HOLE COVER LH

(a) Remove the 2 bolts and trim bracket.

(b) Disconnect the 2 connectors.
(c) Using a screwdriver, remove the clip indicted by the arrow mark and wire.

HINT: Tape the screwdriver tip before use.

(d) Remove the service hole cover.

NOTICE: Remove the remaining tape on the door side.

7. REMOVE REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH
8. REMOVE REAR DOOR WINDOW FRAME MOULDING REAR LH
9. REMOVE REAR SPEAKER ASSEMBLY
10. REMOVE REAR DOOR WINDOW FRAME SUBASSEMBLY REAR LOWER LH

(a) Temporarily install the power window regulator switch.
(b) Lower the glass as it lower.
(c) Remove the glass run.
(d) Remove the bolt, nut and frame.
(e) Remove the power window regulator switch.

11 REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH

(a) Remove the glass from the regulator.

NOTICE: Be careful not to damage the glass.

12. REMOVE REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH

(a) Disconnect the window regulator connector.
(b) Loosen bolt A shown in the illustration.
(c) Remove the 3 bolts and window regulator.

HINT: Remove the window regulator through the service hole.

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

(d) Remove bolt A from the window regulator.

13. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH REAR

(a) Using a T25 "torx" driver, remove the 3 screws and motor.

14. REMOVE REAR DOOR WITH MOTOR LOCK ASSEMBLY LH

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

HINT: Remove the door lock through the service hole.

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

(b) Remove the door lock wire harness packing.

15. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH

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

16. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) Remove the handle by sliding and pulling it in the direction indicated by the arrow mark in the illustration.

NOTICE: If the release plate is not pulled and held when removing the handle, the release plate will interfere with the handle and become damaged.

(b) Remove the outside handle pad front and rear.

17. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

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

(b) Using pliers, pinch the clip and remove the handle frame, as shown in the illustration.

HINT: Remove the handle frame through the service hole.

NOTICE: Be sure to remove the outside handle frame together with the clip, because the clip will be damaged if the clip remain attached to the door panel.

18. REMOVE REAR DOOR CHECK ASSEMBLY LH

(a) Remove the 3 bolts and door check.

HINT: Remove the door check through the service hole.

19. REMOVE REAR DOOR WEATHERSTRIP LH
(a) Using a clip remover, detach the clips and remove the weatherstrip.

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

REASSEMBLY

HINT:
- Use the same procedure for the RH side and LH side.
- The procedures listed below are for the LH side.
- A bolt without a torque specification is shown in the standard bolt chart.

1. INSTALL REAR DOOR WEATHERSTRIP LH
2. INSTALL REAR DOOR CHECK ASSEMBLY LH
(a) Apply MP grease to the sliding areas of the door check.
(b) Install the door 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 upward.

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

(d) Install the door check to the body panel with the bolt.
Torque: 30 Nm (306 kgf-cm, 22 ft.-lbf)

3. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH

(a) Apply MP grease to the sliding areas of the frame.
(b) Using a T30 "torx" socket wrench, install the handle frame with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in.-lbf)

4. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH

(a) Install the outside handle pad front and rear.
(b) Install the handle by pushing it in the direction indicated by the arrow mark in the illustration.

NOTICE: If the release plate is not pulled and held when installing the handle, the release plate will interfere with the handle and become damaged.

5. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH

(a) Using a T30 "torx" socket wrench, install the outside handle cover with the screw.
Torque: 4.0 Nm (41 kgf-cm, 35 in.-lbf)

6. INSTALL REAR DOOR WITH MOTOR LOCK ASSEMBLY LH

(a) Apply MP grease to the sliding and rotating areas of the door lock.
(b) Install a new door lock wire harness packing.

NOTICE:
- When reinstalling a door lock, always use new packing.
- Do not allow grease or dirt to contaminate the gap between the door panel and packing.
- Old packing or damaged packing cannot effectively protect against water. Water will damage the door lock.

(c) Attach the door lock with the release plate of the handle, and then set it to the door panel.

NOTICE: Make sure that the release plate of the frame is securely engaged with the door lock.

(d) Apply adhesive to the threads of the 3 screws.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
(e) Using a T30 "torx" socket wrench, install the door lock with the 3 screws.
Torque: 5.0 Nm (51 kgf-cm, 44 in.-lbf)

(f) Connect the door lock connector.

7. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY LH REAR

(a) Using a T25 "torx" driver, install the motor with the 3 screws.
Torque: 5.4 Nm (55 kgf-cm, 48 in.-lbf)

8. INSTALL REAR DOOR WINDOW REGULATOR SUBASSEMBLY LH

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

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

(b) Loosely screw bolt A onto the window regulator.
(c) Insert the window regulator into the door panel. Use bolt A to hang the window regulator on the door panel.
(d) Install the window regulator with the 3 bolts and bolt A.
Torque: 8.0 Nm (82 kgf-cm, 71 in.-lbf)

(e) Connect the window regulator connector.

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

9. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH

(a) Install the door glass in the regulator.
10. INSTALL REAR DOOR WINDOW FRAME SUBASSEMBLY REAR LOWER LH

(a) Install the frame with the bolt and nut.
Torque: 8.0 Nm (82 kgf-cm, 71 in.-lbf)

11 INSTALL REAR SPEAKER ASSEMBLY
12. INSTALL REAR DOOR WINDOW FRAME MOULDING REAR LH
13. INSTALL REAR DOOR GLASS WEATHERSTRIP ASSEMBLY OUTER LH
14. INSTALL REAR DOOR SERVICE HOLE COVER LH

(a) Apply butyl tape to the door, as shown in the illustration.
(b) Install the 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) Connect the 2 connectors and install the wire.

(d) Install the trim bracket with the 2 bolts.
15. INSTALL REAR DOOR INSIDE HANDLE SUBASSEMBLY LH

(a) Move the inside handle in the direction indicated by the arrow in the illustration to install the inside handle.
(b) Connect the 2 cables to the inside handle.

16. INSTALL REAR DOOR TRIM BOARD SUBASSEMBLY LH

(a) Attach the 7 clips and install the trim board.
(b) Install the screw as shown in the illustration.
17. INSTALL REAR DOOR ARMREST BASE PANEL UPPER LH

(a) Attach the 2 claws and install the switch to the armrest base panel upper.
(b) Connect the switch connector.
(c) Attach the 8 claws and clip to install the armrest base panel together with the switch.
(d) Install the screw.

18. INSTALL REAR DOOR REAR GUIDE BRACKET GARNISH LH

(a) Using a cloth, remove the tape from the garnish.
(b) Clean the contact surface of the door panel with a shop rag saturated with white gasoline.
(c) Clean the outer circumference of the garnish with white gasoline.
(d) Apply new double-sided tape to the garnish, as shown in the illustration.

(e) Using a heat light, heat the door panel and garnish.

NOTICE: Do not heat the door panel and garnish excessively.

(f) Remove the peeling paper from the moulding face.

HINT: Be careful that dirt or foreign objects do not stick to the adhesive when removing the peeling paper.

(g) Install the garnish.

NOTICE: Use steady pressure with your thumbs on the garnish, not excessive force.

19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
20. PERFORM INITIALIZATION
(a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.