Rear End Door Assembly Removal and Installation (Hatchback)

Rear End Door Assembly Removal and Installation (Hatchback)

WARNING:

The rear end door is very heavy with the door balancers detached. The door can cause personal injury if you are not careful when handling it.

Be very careful when opening and closing the rear end door after the door balancers have been detached from the door.

Rear End Door Assembly Components (Hatchback)

Removal

1) Remove rear end door trim (1).
2) Remove related section of head lining and rear trim.
3) Disconnect rear end door harness couplers (2) and washer hose (3).
4) Remove rear end door balancers (4).
5) Remove door hinge nuts (5) and remove rear end door assembly (6).






WARNING:
Improperly handling or disposing of the rear end door balancers can result in personal injury.
- Never try to disassemble a balancer. The gas inside the balancer's cylinder can cause personal injury.
- Before discarding any rear end door balancer, a hole must be drilled in the cylinder part using a 2 to 3 mm (0.08 to 0.12 in.) drill (2) to release the inside gas. Be sure to wear goggles when drilling the hole because metal chips produced by the drilling will be propelled by the gas discharged through the hole and may injure your eyes.






NOTE:
Failure to take proper precautions when handling the removed rear end door balancers (dampers) can cause damage to balancers or can cause them not to work properly after reinstallation.
- Do not scratch the exposed surface of the piston rod. Also, do not allow paint or oil to touch the surface of the piston rod.
- Do not turn the piston rod with the balancer fully extended.

Installation

Reverse removal procedure noting the following.

- Tighten rear end door balancer bolt to specified torque referring to Rear End Door Assembly Components (Hatchback) Rear End Door Assembly Components (Hatchback).
- Secure wiring harness (1).






- Adjust door latch striker position by referring to Removal and Installation (Hatchback) Rear End Door Lock Assembly Removal and Installation (Hatchback).
- Adjust door cushion so that door contacts body when closed.
- Apply sealant to contact face "A" of door hinge (1) and apply grease to rotating part "B" of hinge (1).
Specified sealant and grease.

"A" Sealant: 99000-31110 (SUZUKI Bond No.1215)

"B" Grease: 99000-25011 (SUZUKI Super Grease A)