Reassembly

DOOR / HATCH: REAR DOOR: REASSEMBLY

1. REPAIR INSTRUCTION (w/ Black Out Tape)

2. INSTALL NO. 2 BLACK OUT TAPE (w/ Black Out Tape)

3. INSTALL NO. 3 BLACK OUT TAPE (w/ Black Out Tape)

4. INSTALL REAR DOOR BELT MOULDING ASSEMBLY

5. INSTALL REAR DOOR CUSHION

(a) Engage the 2 guides and 2 clips, and install a new rear door cushion with double-sided tape.





6. INSTALL REAR DOOR FRAME GARNISH

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





7. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY

(a) Apply MP grease to the sliding parts of the rear door outside handle frame sub-assembly.

(b) Engage the claw (A) and install the rear door outside handle frame sub-assembly.





(c) Engage the 2 claws (B).

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 2 claws to install the rear door front outside handle pad.





(b) Using a "TORX" socket wrench (T30), install the screw.





Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

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 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 3 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.





Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

12. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Power Door Lock)

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





13. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Power Door Lock)

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





(b) Engage the 3 claws.





14. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Power Door Lock)

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





15. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Power Door Lock)

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





(b) Engage the claw.





16. INSTALL REAR DOOR LOCK ASSEMBLY (w/o Power Door Lock)

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

(b) Insert the rear door lock assembly to the release plate of the rear door outside handle frame sub-assembly, and set it to the rear door panel.





(c) Make sure that the release plate of the rear door outside handle frame sub-assembly is securely connected to the rear door lock assembly.

(d) 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)

17. INSTALL REAR DOOR LOCK ASSEMBLY (w/ Power Door Lock)

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 release plate of the rear door outside handle frame sub-assembly, and set it to the rear door panel.





(d) Make sure that the release plate of the rear door outside handle frame sub-assembly 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.

18. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY (w/ Power Window)

NOTICE:
The regulator arm must be below the intermediate position when installing the rear power window regulator motor assembly.

(a) Using a "TORX" socket wrench (T25), install the rear 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 uses self-tapping screws to thread new installation holes.

(b) Connect a positive (+) lead of the battery to terminal 2, and a negative (-) lead to terminal 1 of the rear power window regulator motor assembly to move the lift arm to the position as shown in the illustration.





19. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY (w/o Power Window)

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





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

20. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY (w/ Power Window)

(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 rear door window regulator sub-assembly.

(d) Tighten the temporary bolt and 3 bolts to install the rear door window regulator sub-assembly.

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

(e) Connect the connector.

21. INSTALL REAR DOOR GLASS RUN

(a) Install the rear door glass run.





22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY

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





23. INSTALL REAR DOOR REAR GUIDE SEAL

(a) Install the rear door rear guide seal with the screw.





24. INSTALL REAR DOOR REAR WINDOW GUIDE SUB-ASSEMBLY

(a) Insert the rear door rear window guide sub-assembly in the direction indicated by the arrow in the illustration.





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

(c) Install the rear door rear window guide sub-assembly with the bolt and 3 screws.





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

25. INSTALL REAR DOOR WEATHERSTRIP

(a) Engage the 16 clips and install the rear door weatherstrip.





26. INSTALL REAR DOOR CHECK ASSEMBLY

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





Bolt (1) - Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

Bolt (2) - Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

27. INSTALL REAR DOOR SERVICE HOLE COVER (w/o Power Door Lock)

(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) Attach the rear door service hole cover by using the reference points on the rear door panel.

NOTICE:
Securely install the rear door service hole cover preventing wrinkles and air bubbles.

28. INSTALL REAR DOOR SERVICE HOLE COVER (w/ Power Door Lock)

(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) Attach the rear door service hole cover by using the reference points on the rear door panel.

NOTICE:
Securely install the rear door service hole cover preventing wrinkles and air bubbles.

(d) Connect the connector.

29. INSTALL REAR SPEAKER ASSEMBLY Installation

30. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP

(a) Install the rear door inner glass weatherstrip.





31. 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 door inside handle sub-assembly.





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





32. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY

(a) Connect each connector.

(b) Engage the rear door trim board with the 4 claws on the rear door inner glass weatherstrip.





(c) Engage the 8 clips to install the rear door trim board sub-assembly to the rear door panel.

(d) Install the 3 screws.





33. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY (w/ Power Window)

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





34. INSTALL REAR DOOR ARMREST UPPER BASE PANEL (w/o Power Window)

(a) Engage the clip and 8 claws, and install the rear door armrest upper base panel.





35. INSTALL REAR DOOR ARMREST UPPER BASE PANEL (w/ Power Window)

(a) Connect the connector.

(b) Engage the clip and 8 claws, and install the rear door armrest upper base panel.





36. INSTALL REAR DOOR INSIDE HANDLE BEZEL

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





37. INSTALL REAR DOOR WINDOW REGULATOR HANDLE ASSEMBLY (w/o Power Window)

(a) Temporarily install the rear door window regulator handle assembly and fully close the window glass.

(b) Install the rear door regulator inside handle plate.

(c) Install the snap ring to the rear door window regulator handle assembly.

(d) Install the rear door window regulator handle assembly as shown in the illustration.





38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL