Rear Door: Service and Repair

DOOR

REMOVAL




1. Disconnect and isolate the negative battery cable.
2. Disconnect the door wire harness connector (5) from the body wire harness (8).
3. Using a grease pencil or equivalent, mark the location of the door hinges (2 and 7) on the door (4).

NOTE: The epoxy bonded washers do not need to be separated from the hinges. If the washers are removed, the door may need to be re-adjusted.

4. Support the door with a suitable lifting device and remove the two nuts (1) and two bolts (9) that secure the door to the hinges.
5. Carefully remove the door from the hinges.
6. If required, remove the two studs (3 and 6) from the door.

INSTALLATION




1. If removed, install the two studs (3 and 6) into the door (4).
2. Carefully position the door onto the hinges (2 and 7) and support the door with a suitable lifting device.

NOTE: If the epoxy bonded washers are separated from the hinges, the door may need to be adjusted.

3. If removed, install the epoxy bonded washers.
4. Loosely install the two nuts (1) and the two bolts (9) that secure the door to the hinges.
5. Align the door to the hinges using the reference marks made during the removal procedure and tighten the nuts and bolts to 28 N.m (21 ft.lbs.).
6. Connect the door wire harness (5) to the body wire harness (8).
7. Reconnect the negative battery cable.
8. If necessary, adjust the door.