Repair Procedure
REPAIR PROCEDURE
1. Lower the affected rear door glass to the bottommost limit of travel.
2. Remove the covers from the screw in the armrest and the inner door release handle. Remove the screws.
3. Uncover and remove the screw at the forward edge of the door trim panel.
4. Use a trim removal tool to release the door trim clips around the perimeter of the door and pull the trim clear of the door assembly.
5. Use masking tape to mark the adjustment of the inside handle cable (orange clip). This will reduce the possibility of having to re-adjust the cable during reassembly.
6. Disconnect the inside lock cable and the inside handle cable by rotating the retaining clips and lifting the end of the cables clear.
7. Disconnect the connector for the power window switch. Set the door trim aside.
NOTE:
If the inside handle cable needs adjustment when re-installed, refer to the service manual for the adjustment procedure.
CAUTION:
Take care not to damage the plug on the door trim.
8. Disconnect the electrical connector for the speaker.
9. Remove the bracket for the armrest.
10. Peel off the waterproof film.
NOTE:
Be careful to not tear or stretch the film. Do not allow the black adhesive material to contact interior trim parts.
11. Remove the door cavity filler.
12. Remove the inner beltline weather strip.
13. Remove the 2 outer beltline molding retaining screws as indicated.
NOTE:
The rear screw is covered by the weatherstrip. Move the weatherstrip to one side to remove the screw. Lift the beltline outer molding from inside of the vehicle using a trim remover.
14. Remove the outer beltline molding as shown.
CAUTION:
Take care when removing the run channel. The unsupported door glass may contact the sash or other panels causing damage to the glass.
15. Remove the window run channel.
16. Disconnect the glass from the regulator assembly and slide it to the fully closed position.
17. Hold the glass in the fully closed position using a commercially available glass holder.
18. Remove the lower sash retaining bolt.
19. Remove the harness attached to the lower sash.
20. Remove the lower sash by sliding it downward.
21. Check the Superscreen to determine the vehicle's production date. Only perform step 22 if the vehicle was built BEFORE October 10, 2007. If the vehicle was built on or after October 10, 2007, skip step 22.
22. Enlarge the lower sash retaining bolt hole in the door a maximum of 2 mm using a small round file. The direction of filing should be toward the front of the door and slightly up.
CAUTION:
Treat the area with Rusfre 1000 (part # A9907KIX01) anti-corrosion treatment (or equivalent) prior to reassembly, to prevent corrosion of the bare metal where it was filed. Insure that all metal filings are cleaned from inside the door cavity.
23. While holding the door glass, remove the holding tool and CAREFULLY lower the glass past the regulator to allow for accurate measuring of the gap between the inner and outer door panels.
CAUTION:
Take extra care to not scratch the glass. Cover the regulator with a shop towel to protect the glass.
24. Measure the gap between the door inner panel and the door outer panel at the 7 points indicated in the illustration above. If there is an area that measures less than 33.5 mm, adjust the gap to be within spec (34 mm +/- 0.5 mm, 1.34" +/- 0.02") by bending the flange of the inner door panel to enlarge it.
25. If adjustment is necessary, use pliers or a similar tool to carefully bend the inner door inner panel flange and increase the gap between the inner and outer flanges. Bend the areas at the spot welds (narrow areas) first, then bend other areas as needed.
26. Reinstall the lower rear door sash. Insure the that top of the lower rear door sash is inserted into the upper rear door sash as shown. Insure that the door glass is positioned inside the sash. Adjust the position of the lower retaining bolt to be secured at the forward-most position in the enlarged hole.
27. Reinstall the run channel. Install a new run channel if the existing part is damaged.
28. Resecure the harness to it's location on the lower door sash.
29. Reattach the glass to the regulator.
30. Reinstall the door outer beltline molding.
31. Reinstall the inner beltline weatherstrip (install a new part for vehicles built before June 10, 2008).
32. Reinstall the door cavity filler.
33. Route the door lock cable, door handle cable and the wiring harness through the waterproof film.
34. Reinstall the waterproof film, the armrest bracket and connect the speaker wire.
NOTE:
Refer to the workshop manual for instructions to re-install the waterproof film.
35. Install the inside lock cable and the inside handle cable to the inner door release mechanism. Check that it releases properly. Compare to the handle on the opposite door to confirm the release point.
NOTE:
If the inside handle cable needs adjustment when re-installed, refer to the service manual for the adjustment procedure.
36. Connect the power window switch harness to the power window switch.
37. Install the door trim and all screws and screw covers.
38. Perform the learning procedure for the power window fully closed position (refer to the service manual, Section 42A - Body ), and confirm all door functions (door locking, door opening and closing, speaker) work normally.