Rear Door: Service and Repair

OVERHAUL

HINT:
- The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
- Use the same procedures for the RH side and LH side.
- The procedures listed below are for the LH side.
- A bolt without a torque specification is shown in the standard bolt chart.




1. REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH
a. Using a screwdriver, disengage the 3 claws and remove the rear door inside handle bezel plug LH.

HINT: Tape the screwdriver tip before use.




2. REMOVE REAR DOOR ARMREST BASE PANEL UPPER LH
a. Using a screwdriver, disengage the 2 clips and 4 claws, and remove the armrest base panel upper LH with the power window regulator master switch.
b. Disconnect the switch connector.




3. REMOVE REAR DOOR TRIM BOARD SUB-ASSEMBLY LH
a. Remove the 3 screws.




b. Using a clip remover, disengage the 7 clips (A) and 4 clips (B) on top.
c. Remove the trim inboard.

HINT: If a clip cannot be reached with the clip remover, pull on the lower trim to remove it.




d. Disconnect the 2 cables.
e. Disconnect the wire harness connector from the courtesy lamp.




4. REMOVE REAR DOOR INSIDE PANEL BRACKET NO.1 LH
a. Remove the 4 screws and the rear door inside panel bracket No.1 LH.

5. REMOVE REAR SPEAKER ASSEMBLY NO.2
6. REMOVE REAR SPEAKER ASSEMBLY




7. REMOVE REAR DOOR SERVICE HOLE COVER LH
a. Remove the rear door service hole cover LH.

NOTE: Remove the remaining tape on the door side.

8. REMOVE REAR DOOR BELT MOULDING ASSEMBLY LH
9. REMOVE REAR DOOR WINDOW FRAME MOULDING FRONT LH
10. REMOVE REAR DOOR MOULDING SUB-ASSEMBLY OUTSIDE LH
11. REMOVE REAR DOOR GLASS WEATHERSTRIP INNER LH
12. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY LH
a. Remove the screw, 2 bolts and the rear door window division bar sub-assembly LH.




13. REMOVE REAR DOOR WINDOW GLASS LH
a. Remove the rear door window glass LH as shown in the illustration.




14. REMOVE REAR DOOR GLASS SUB-ASSEMBLY LH
a. Separate the arm of the rear door window regulator from the rail of the rear door glass.
b. Remove the rear door glass sub-assembly LH

NOTE: Be careful not to damage the glass.




15. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Remove the 4 bolts and the rear door window regulator sub-assembly LH.




16. REMOVE POWER WINDOW REGULATOR MOTOR ASSEMBLY RH REAR
a. Using a torx(R) wrench (T25), remove the 3 torx(R) screws and the power window regulator motor assembly RH rear.

17. REMOVE REAR DOOR WINDOW RUN LH




18. REMOVE REAR DOOR W/MOTOR LOCK ASSEMBLY LH
a. Disconnect the door lock connector.
b. Using a torx(R) socket wrench (T30), remove the 3 torx(R) screws and rear door w/ motor lock assembly LH.

HINT: Remove the door lock through the service hole.

NOTE: Be careful when removing the bolts as the door lock may fall and be damaged.




19. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH
a. Using a torx(R) socket wrench (T30), loosen the torx(R) screw and remove the cover with the door lock key cylinder installed.




20. REMOVE REAR DOOR OUTSIDE HANDLE ASSEMBLY LH
a. Remove the handle by sliding and pulling it in the direction indicated by the arrow in the illustration.
b. Remove the outside handle pad front and rear.

NOTE: If the bellcrank lever is not pulled and held when removing the handle, the release plate will interfere with the handle and be damaged.




21. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (W/O SMART KEY SYSTEM)
a. Using a torx(R) socket wrench (T30), loosen the torx(R) screw and remove the rear door outside handle frame sub-assembly LH.




22. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (W/ SMART KEY SYSTEM)
a. Disconnect the connectors.




b. Disconnect the clamp.
c. Using a torx(R) socket wrench, loosen the torx(R) screw and remove the rear door outside handle frame sub-assembly LH.

23. REMOVE REAR DOOR OUTSIDE HANDLE PAD FRONT
24. REMOVE REAR DOOR OUTSIDE HANDLE PAD REAR




25. REMOVE REAR DOOR CHECK ASSEMBLY LH
a. Remove the bolt, 2 nuts and the rear door check assembly LH.

HINT: Remove the door check through the service hole.

NOTE: Be careful when removing the bolts as door check may fall and be damaged.

26. REMOVE REAR DOOR WEATHERSTRIP LH




27. INSTALL REAR DOOR CHECK ASSEMBLY LH
a. Apply MP grease to the sliding areas of the door check.
b. Install the door check to the door panel with the 2 nuts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

c. Apply adhesive to the threads of the bolt.

Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

d. Install the door check to the body panel with the bolt.

Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)

28. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (W/O SMART KEY SYSTEM)
a. Using a torx(R) wrench (T25), install the rear door outside handle frame sub-assembly LH with the torx(R) screw.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)

29. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY LH (W/ SMART KEY SYSTEM)
a. Using a torx(R) wrench (T25), install the rear door outside handle frame sub-assembly LH with the torx(R) screw.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)




30. INSTALL REAR DOOR OUTSIDE HANDLE COVER RH
a. Using a torx(R) socket wrench (T30), install the cover (with the door lock key cylinder installed) with the torx(R) screw.

Torque: 4.0 N.m (41 kgf.cm, 37 in.lbf)

31. INSTALL REAR DOOR W/MOTOR LOCK ASSEMBLY LH
a. Apply MP grease to the sliding and rotating areas of the door lock.
b. Install a new door lock wire harness packing.

NOTE:
- When reinstalling a door lock, always use new packing.
- Do not allow grease or dirt to contaminate the gap between the door panel and packing.
- Water will damage the door lock.
- Old packing or damaged packing cannot effectively protect the door lock against water.

c. Insert the control rod into the door lock, and then set it to the door panel.

NOTE: Make sure that the rod is securely engaged with the lock.




d. Apply adhesive to the threads of the 3 torx(R)screws.

Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent

e. Using a torx(R) socket wrench (T30), install the door lock with the 3 torx(R)screws.

Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

f. Connect the door lock connector.




32. INSTALL POWER WINDOW REGULATOR MOTOR ASSEMBLY RH REAR
a. Using a torx(R) wrench (T25), install the power window regulator motor assembly RH rear with the 3 torx(R) screws.

Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf)




33. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY LH
a. Install the rear door window regulator sub-assembly LH with the 4 bolts.

Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)




34. INSTALL REAR DOOR SERVICE HOLE COVER LH
a. Apply butyl tape to the door.
b. Install the rear door service hole cover LH, as shown in the illustration.

HINT:
- There should be no wrinkles or folds after attaching the service hole cover.
- Check if the service hole cover is securely attached.

For Power Window Initialization/Reset Initialization