Reassembly

ENGINE HOOD / DOOR: REAR DOOR: REASSEMBLY

1. REPAIR INSTRUCTION

2. INSTALL REAR DOOR LOWER OUTSIDE STRIPE

3. INSTALL REAR DOOR OUTSIDE STRIPE

4. INSTALL REAR DOOR UPPER WINDOW FRAME MOULDING

5. INSTALL REAR DOOR FRONT WINDOW FRAME MOULDING

6. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

7. 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) Engage the claw to install the rear door outside handle frame sub-assembly.





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

8. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD

(a) Engage the 2 claws to install the rear door rear outside handle pad.





9. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD

(a) Engage the 3 claws to install the rear door front outside handle pad.





10. 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 the release plate will be damaged.

(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 toward the front of the vehicle to install it.

11. INSTALL REAR DOOR OUTSIDE HANDLE COVER

(a) Engage the claws to install the rear door outside handle cover.





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





12. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY

(a) Install the rear door inside locking cable assembly.





(b) Engage the 3 claws.





13. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY

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





(b) Engage the claw.





14. INSTALL REAR DOOR LOCK ASSEMBLY

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

(a) Apply MP grease to the sliding parts of the rear door lock assembly.

(b) Install a new door lock wiring harness seal 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 : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(f) Connect the connector.

15. 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 Nm (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.

16. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY

(a) Apply MP grease to the sliding parts of 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 : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(e) Connect the connector.

17. INSTALL REAR DOOR FRAME GARNISH

(a) Engage the clip and install a new rear door frame garnish.





18. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.





19. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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





20. INSTALL REAR DOOR QUARTER WINDOW GLASS

(a) Install the rear door quarter window glass to the rear door quarter window weatherstrip.

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





21. INSTALL REAR DOOR LOWER WINDOW FRAME SUB-ASSEMBLY

(a) Insert the rear door lower window frame sub-assembly from above.

(b) Install the rear door glass run to the rear door lower window frame sub-assembly.

(c) Install the rear door lower window frame sub-assembly with the 2 bolts and screw.





22. INSTALL REAR DOOR WEATHERSTRIP

(a) Engage the 20 clips and install the rear door weatherstrip.





23. INSTALL REAR DOOR CHECK ASSEMBLY (for TMC Made)

(a) Install the rear door check assembly with the 3 bolts.





Bolt (A) - Torque : 26 Nm (265 kgf-cm, 19 ft-lbf

Bolt (B) - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf

24. INSTALL REAR DOOR CHECK ASSEMBLY (for TMMK Made)

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





Bolt - Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

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

25. 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 the 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.

26. INSTALL REAR DOOR INSIDE PANEL REINFORCE

(a) Install 4 new grommets.

(b) Install a new rear door inside panel reinforce with the 4 screws.





27. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

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





28. INSTALL REAR DOOR ARMREST BASE PANEL UPPER

(a) Engage the 4 claws.





(b) Install the rear door armrest base panel upper with the 7 screws.

29. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY

(a) Engage the 2 claws and install the rear power window regulator switch assembly.





30. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY

(a) Connect the rear door lock remote control cable and rear door inside locking cable to the rear inside handle.





(b) Engage the 2 claws and install the rear door inside handle sub-assembly.





31. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) Engage the claw to install the No. 1 door scuff plate clamp.





(b) Connect each connector.

(c) Engage the rear door trim board with the 4 clips of the rear door inner glass weatherstrip.





(d) Engage the 7 clips to install the rear door trim board to the rear door panel.





(e) Install the 3 screws.

32. INSTALL DOOR ASSIST GRIP COVER

(a) Engage the 6 claws and install the door assist grip cover.





33. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG

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





34. INITIALIZE POWER WINDOW CONTROL SYSTEM

Programming and Relearning