Rear Door: Service and Repair

OVERHAUL

HINT:
- The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
- Use the same procedures on the RH side as on the LH side.




1. REMOVE POWER WINDOW REGULATOR SWITCH ASSEMBLY REAR
a. Using a screwdriver, disengage the 2 claws and 2 clips, and remove the inside handle bezel.

HINT: Tape the screwdriver tip before use.

b. Disengage the 2 claws and remove the switch.




2. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH
a. Using a screwdriver, disengage the 3 claws and remove the bezel plug.

HINT: Tape the screwdriver tip before use.




3. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the armrest cover.
b. Remove the 2 screws.
c. Using a clip remover, remove the 13 clips and remove the trim board.

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

d. Disconnect the 2 cables from the inside handle.




4. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER LH
a. Remove the weatherstrip inner pulling it upward in the direction indicated by arrow mark in the illustration.

5. REMOVE REAR DOOR BELT MOULDING ASSEMBLY LH
6. REMOVE REAR DOOR WINDOW FRAME MOULDING SUB-ASSEMBLY LH
7. REMOVE REAR DOOR ARMREST SET BRACKET LH
a. Remove 2 screws and armrest set bracket.




8. REMOVE REAR DOOR SERVICE HOLE COVER LH
a. Using a clip remover, disengage the clamps.
b. Remove the service hole cover.

NOTE: Remove the remaining tape on the door side.




9. 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: Do not damage the door glass.

a. Remove the glass run.
b. Remove the 2 bolts, screw and division bar.




c. Rotate the division bar by 90 ° and pull it upward, as shown in the illustration.




10. REMOVE REAR DOOR QUARTER WINDOW GLASS LH
a. Remove the window glass in the direction indicated by arrows in the illustration.

NOTE: Do not damage the glass.

11. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP LH




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

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




13. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Disconnect the window regulator connector.
b. Remove the 3 bolts and window regulator.

NOTE: When the bolts are removed, the window regulator may fall and become deformed.

HINT: Remove the window regulator through the service hole.

14. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY LH
a. Place matchmarks on the regulator motor gear and regulator gear.
b. Using a torx driver (T25), remove the 3 screws and regulator motor.




15. REMOVE REAR DOOR LOCK ASSEMBLY LH
a. Disconnect the door lock connector.
b. Using a torx socket wrench (T30), remove the 3 screws and door lock.

HINT: Remove the door lock through the service hole.




16. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), loosen the screw and remove the outside handle cover.




17. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH
a. Pull and hold the release plate of the outside handle frame, as shown in the illustration.




b. Pushing and pulling the outside handle in the direction indicated by arrow mark in the illustration, remove the handle.

NOTE: If the release plate is not pulled and held when removing the outside handle, then the release plate will interfere with the outside handle and damage the release plate.

c. Remove the outside handle pads front and rear.




18. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Using a torx socket wrench (T30), loosen the screw.
b. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration and remove it.

HINT: Remove the outside handle frame through the service hole.




19. REMOVE REAR DOOR CHECK ASSEMBLY LH
a. Remove the check cover.
b. Remove the 2 nuts, bolt and door check.

HINT: Remove the door check through the service hole.




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

HINT: If the clip is damaged, replace it for a new clip.




21. INSTALL REAR DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the door check.
b. Install the door check to the door panel with the 2 nuts.

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

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

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: 27 Nm (275 kgf.cm, 20 ft.lbf)

e. Install the check cover.




22. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH
a. Install the open rod to the outside handle frame.
b. Slide the outside handle frame in the direction indicated by the arrow mark in the illustration.
c. Using a torx socket wrench (T30), install the outside handle frame with the screw.

Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)

NOTE: Insert a cover between the nut and the door panel.

d. Install the outside handle pads front and rear.




23. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY LH
a. Pull and hold the release plate of the outside handle frame, as shown in the illustration.




b. Pushing the outside handle in the direction indicated by the arrow mark in the illustration, install the outside handle.

NOTE: If the release plate is not pulled and held when installing the outside handle, the release plate will interfere with the outside handle. It will damage the release plate.




24. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH
a. Using a torx socket wrench (T30), install the outside handle cover with the screw.

Torque: 7.0 Nm (71 kgf.cm, 62 in.lbf)

25. INSTALL REAR DOOR 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.

NOTE:
- If reusing a removed door lock, replace the packing in the connecting part with a new packing.
- Be careful that no grease and dirt sticks to the packing surface in the connecting part.
- Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock.

c. Engage the door with the release plate of the outside handle and then set it to the door panel.

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




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

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

Torque: 5.0 Nm (51 kgf.cm, 42 in.lbf)

f. Connect the door lock connector.

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

Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf)




27. 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 3 bolts in the order as shown in the illustration.

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

NOTE: Be careful not to drop the rear door window regulator, as this may cause deformation.

c. Connect the window regulator connector.




28. INSTALL REAR DOOR GLASS SUB-ASSEMBLY LH

NOTE: Be careful not to drop the glass, as this may cause deformation.

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.




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

NOTE: Do not damage the glass.

b. Install the quarter window glass, as shown in the illustration.




30. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH
a. Insert the division bar into the door panel, then rotate it by 90°, as shown in the illustration.
b. Mount the door glass to the window regulator.




c. Tighten the division bar with the 2 bolts and screw.

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

d. Install the glass run.
e. Reset the power window motor.
f. Inspect operation of the power window.

HINT: When the installation point of the door glass does not match, adjust the window regulator position in manual operation.

1. Connect the power window switch to the wire harness and turn the ignition switch ON.
2. Repeat UP and DOWN operation several times in manual operation.




31. INSTALL REAR DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door panel, as shown in the illustration.

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, confirm the sealing condition.

For Power Window Initialization/Reset [1][2]Programming and Relearning