Rear Door: Service and Repair

Rear Door

Removal





1
NOTE:
The rear door is manufactured from mild steel, it contains a side impact reinforcement manufactured from boron steel.
The rear door is serviced as a separate bolt-on panel.
2 For additional information relating to this repair procedure please see the following: For additional information, refer to Health and Safety Precautions Health and Safety Precautions
For additional information, refer to Body Repairs
For additional information, refer to Corrosion Protection
For additional information, refer to Body and Frame
3
NOTE:
If the procedure includes removal of the rear door components, the battery can remain connected to aid their removal and disconnected afterwards.
Disconnect the battery ground cable. For additional information, refer to Battery Disconnect and Connect Battery Disconnect and Connect
4
NOTE:
For new rear door installation, this step may be carried out later in the removal procedure.
Disconnect the rear door wiring harness, accessed behind the grommet on the B-pillar.
5
NOTE:
For new rear door installation, this step may be carried out later in the removal procedure.
Release the rear door check strap from the body.




6
NOTE:
This step is for removing the fully trimmed rear door for access only, for installing a new front door, continue to removal step 7.
Remove the rear door upper and lower hinge pivot bolts and lift the rear door to remove.
7 Remove the rear door fixed window glass. For additional information, refer to Rear Door Fixed Window Glass Rear Door Fixed Window Glass
8 Remove the rear door latch. For additional information, refer to Rear Door Latch Service and Repair
9 Remove the rear door outer window frame mouldings.

10 Remove the rear door weatherstrips.

11 Remove the rear door wiring harness.

12 Remove the rear door impact absorbers.

13 Remove the rear door check strap.

14 Remove the rear door glass run felt.

15 Remove any miscellaneous rear door clips, grommets and blanking covers.





16
NOTE:
If new hinges are being fitted, install the complete hinges to the B-pillar.
Remove the upper and lower rear door hinge bolts and remove the rear door.

Installation
1
NOTE:
If the rear door has been removed for access only, it can be installed back on to its upper and lower hinge pivots and secured with the upper and lower hinge pivot bolts.
Offer up the rear door and loosely install the rear door hinge bolts.
2 Check alignment, if correct, proceed to next step, if not, rectify and recheck before proceeding.
3 Tighten the rear door hinge bolts to 30 Nm.




4 When correctly aligned and with the rear door hinge bolts tightened, the new rear door can be removed at its upper and lower hinge pivot bolts for refinishing.
5 The installation of associated panels and components is the reversal of removal procedure.
- Tighten the rear door upper and lower hinge pivot bolts to 30 Nm.