Rear Door: Service and Repair
DISASSEMBLY1. w/o Power window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator handle and plate.
2. REMOVE DOOR INSIDE HANDLE BEZEL
a. Remove the screw.
b. Using a screwdriver, pry out the bezel.
HINT: Tape the screwdriver tip before use.
3. REMOVE DOOR TRIM BOARD
a. Using a screwdriver, remove the door assist grip door panel.
HINT: Tape the screwdriver tip before use.
b. Remove the 2 screws and clip.
c. Insert a screwdriver between the door panel and door trim board to pry the door trim board loose.
HINT: Tape the screwdriver tip before use.
d. Remove the door trim board.
4. w/ Power window:
REMOVE POWER WINDOW SWITCH
a. Disconnect the connector.
b. Using a screwdriver, remove the switch.
HINT: Tape the screwdriver tip before use.
5. REMOVE DOOR INSIDE HANDLE
a. Remove the screw.
b. Disconnect the 2 cables and remove the door inside handle.
6. REMOVE SERVICE HOLE COVER
7. REMOVE REAR DOOR WEATHERSTRIP
Using a screwdriver, remove rear door weatherstrip.
HINT: Tape the screwdriver tip before use.
8. REMOVE DOOR BELT MOULDING
a. Remove the screw.
b. Using a moulding remover, remove the front door belt moulding.
9. REMOVE DOOR SPEAKER
a. Disconnect the connector.
b. Using a drill of less than Dia 4 mm (0.16 in.), drill out the rivet heads and remove the door speaker.
c. Gently and vertically put the drill to the rivet, and cut the rivet flanges.
NOTE:
- Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
- Take care as the cut rivet is hot.
d. Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
e. Using a vacuum cleaner, remove the drilled rivet and their dust from the inside of the door panel.
10. REMOVE DOOR GLASS RUN
11. REMOVE DIVISION BAR
Remove the bolt, screw and division bar.
12. REMOVE REAR DOOR QUARTER WINDOW WEATHERSTRIP AND GLASS
13. REMOVE DOOR GLASS AND WINDOW REGULATOR ASSEMBLY
NOTE:
- Be careful not to drop the door glass and window regulator assembly.
- Do not damage the door glass.
a. w/ Power window:
Disconnect the connector.
b. w/ Power window:
Remove the 3 bolts from the window regulator.
c. w/o Power window:
Remove the 2 bolts from the window regulator.
d. Remove the door glass through the window regulator.
e. Remove the window regulator through the service hole.
f. w/ Power window:
Using a torx wrench, remove the 3 screws and motor.
14. REMOVE DOOR LOCK
a. w/ Power door lock:
Disconnect the connector.
b. Disconnect the 2 links from the outside handle.
c. Remove the 4 screws, bolt and door lock.
15. REMOVE DOOR OUTSIDE HANDLE
Remove the 2 screws and door outside handle.
REASSEMBLY
1. INSTALL DOOR OUTSIDE HANDLE
Install the door outside handle with the 2 screws.
Torque: Screw, Bolt: 2.5 N.m (25 kgf.cm, 22 in.lbf)
2. INSTALL DOOR LOCK
HINT: Apply MP grease to the sliding and rotating parts of the door lock.
a. Install the door lock through the service hole.
b. Install the door lock with the 4 screws and bolt.
Torque: 5.0 N.m (50 kgf.cm, 44 in.lbf)
HINT: Apply adhesive to the 3 screws.
Part No. 08833-00070, THREE BOND 1324 or equivalent
c. Connect the 2 links to the outside handle.
d. w/ Power door lock:
Connect the connector.
3. INSTALL DOOR GLASS AND WINDOW REGULATOR ASSEMBLY
a. w/ Power window:
Install the motor with the 3 screws.
HINT: Apply MP grease to the window regulator rollers.
NOTE:
- Be careful not to damage the door glass.
- Be careful not to drop the door glass and window regulator assembly.
b. Install the window regulator through the service hole.
c. Install the door glass with the 2 nuts to the window regulator lift arm bracket.
d. w/ Power window:
Install the 3 bolts.
Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf)
e. w/o Power window:
Install the 2 bolts.
Torque: 8.5 N.m (85 kgf.cm, 75 in.lbf)
f. Install the door glass to the window regulator.
NOTE: Be careful not to drop the door glass.
g. w/ Power window:
Connect the connector.
4. INSTALL REAR DOOR QUARTER WINDOW GLASS WEATHERSTRIP AND GLASS
5. INSTALL DIVISION BAR
Install the division bar with the bolt and screw.
6. INSTALL DOOR GLASS RUN
7. INSTALL DOOR SPEAKER
a. Using an air riveter or hand riveter, install the door speaker with 3 new rivets.
NOTE:
- Do not prize a riveter, as riveter is damaged, it is not tightened and the mandrel is bent.
- Do not tilt the riveter and disconnect the rivet from the material while handling a riveter, as the materials are not tightened firmly.
- Install the rivet while attaching materials, as they are not tightened firmly.
b. Connect the connector.
8. INSTALL DOOR BELT MOULDING
9. INSTALL REAR DOOR WEATHERSTRIP
10. INSTALL SERVICE HOLE COVER
HINT: Pull out the connector through the service hole cover.
11. INSTALL DOOR INSIDE HANDLE
a. Connect the 2 cables.
b. Install the door inside handle with the screw.
12. w/Power window:
INSTALL POWER WINDOW SWITCH
a. Connect the connector.
b. Install the power window switch.
13. INSTALL DOOR TRIM BOARD
a. Install the door trim board with the 2 screws and clip to the door grip.
b. Install the door assist grip cover.
14. INSTALL DOOR INSIDE HANDLE BEZEL
Install the door inside handle bezel with the screw.
15. w/o Power window:
INSTALL REGULATOR HANDLE
Install the regulator handle and plate with the snap ring.
HINT: With door window fully closed, install the plate and the regulator handle with the snap ring as shown.
For Power Window Initialization/Reset Initialization