Rear Door: Service and Repair
DISASSEMBLY1. REMOVE INSIDE HANDLE BEZEL
a. Using a screwdriver, remove the cover.
HINT: Tape the screwdriver tip before use.
b. Remove the screw.
c. Using a screwdriver, remove the inside handle bezel as shown in the illustration.
HINT: Tape the screwdriver tip before use.
2. REMOVE UPPER ARMREST BASE PANEL WITH POWER WINDOW SWITCH
a. Using a screwdriver, remove the upper armrest base panel with power window switch.
HINT: Tape the screwdriver tip before use.
b. Disconnect the connector.
c. Remove the power window switch from the upper armrest base panel.
3. REMOVE REAR GUIDE BRACKET GARNISH
Using a screwdriver, remove the rear guide bracket garnish.
HINT: Tape the screwdriver tip before use.
4. REMOVE DOOR TRIM
a. Remove the 3 screws and 2 clips.
b. Pull the trim upward to remove it.
c. Using a screwdriver, remove the rear door inner weatherstrip.
d. Remove the 13 screws and rear door armrest.
e. Remove the 7 screws and rear door trim pocket.
5. REMOVE INSIDE HANDLE
a. Remove the screw.
b. Slide the inside handle backward to remove it.
c. Disconnect the 2 cables from the inside handle as shown in the illustration.
6. REMOVE DOOR SPEAKER BOARD
7. REMOVE SERVICE HOLE COVER
a. Disconnect the 2 control cables from the link clamp.
b. Using a clip remover, remove the grommets and link clamp.
c. Remove the service hole cover.
NOTE: Do not tear the cover.
HINT: At the time of reassembly, please refer to the following item.
Bring out the 2 control cables and wire harness through the service hole cover.
8. REMOVE REAR DOOR WEATHERSTRIP
a. Remove the screw from the door check.
b. Using a clip remover, remove the rear door weatherstrip.
c. Reinstall the screw to the door check.
Torque: 25 N.m (260 kgf.cm, 19 ft.lbf)
9. REMOVE REAR DOOR BELT MOULDING
a. Apply protective tape to the outer surface as shown in the illustration, to keep the surface from being scratched.
b. Using a moulding remover, remove the rear door belt moulding.
10. REMOVE REAR DOOR OUTSIDE LOWER MOULDING
a. Using a drill of less than dia 3.2 mm (0.126 in.), drill out the 2 rivet heads.
HINT: Gently and vertically put the drill to the rivet, and cut the rivet flanges.
CAUTION: Take care as the cut rivet is hot.
NOTE: Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
b. Using a clip remover, remove the clip.
c. Remove the rear door outside lower moulding.
d. Using a vacuum cleaner, remove the drilled rivets and their dust from the inside of door panel.
HINT: At the time of reassembly, please refer to the following item.
Using an air riveter with nose piece No. 1 or hand riveter with nose piece No. 1, install the 3 rivets to the front door outside lower moulding.
NOTE:
- At the time of reassembly, please refer to the following items.
- Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
- Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
- Install the rivet while attaching materials, as they are not tightened firmly.
11. REMOVE DOOR GLASS RUN
12. REMOVE REAR DOOR WINDOW GUIDE WITH GUIDE PIECE PLATE
a. Remove the bolt, nut, 3 screws and rear door window guide with guide piece plate.
b. Remove the guide piece plate from the rear door window guide.
13. REMOVE REAR DOOR GLASS
a. Open the door glass until the bolts appear in the service hole.
b. Remove the 2 bolts.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
NOTE: Be careful not to drop the door glass.
c. Pull the door glass upward to remove it.
14. REMOVE WINDOW REGULATOR ASSEMBLY
a. Disconnect the connector, then remove the 4 nuts and window regulator assembly.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
HINT: Remove the window regulator assembly through the service hole.
b. Using a torx driver, remove the 3 torx screws and window regulator motor from the window regulator guide assembly.
HINT:
- At the time of reassembly, please refer to the following items.
- Apply MP grease to the glass guide and rollers of window regulator assembly.
- After installing the window regulator assembly, window regulator assembly need to be re-initialized.
15. REMOVE DOOR LOCK
a. Disconnect the control link from the outside handle.
b. Disconnect the connector.
c. Remove the 3 torx screws and door lock.
Torque:
Bolt: 5.4 N.m (55 kgf.cm, 48 in.lbf)
Screw: 4.9 N.m (50 kgf.cm, 43 in.lbf)
HINT: Remove the door lock through the service hole.
HINT: At the time of reassembly, please refer to the following item.
Apply adhesive to 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Remove the 2 screws and door lock protector from the door lock.
HINT:
At the time of reassembly, please refer to the following item.
Apply MP grease to the sliding and rotating parts of the door lock.
16. REMOVE OUTSIDE HANDLE
Remove the 2 bolts and outside handle.
Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)
REASSEMBLY
Reassembly is in the reverse order of disassembly.
For Power Window Initialization/Reset Programming and Relearning