REAR DOOR REASSEMBLY


  1. REPAIR INSTRUCTION


    1. Clean the vehicle body surface.


      1. Using a heat light, heat the vehicle body surface.

        Heating temperature
        Item Temperature
        Vehicle Body 40 to 60°C (104 to 140°F)

        Note

        Do not heat the vehicle body excessively.

      2. Wipe off any tape adhesive residue with cleaner.

    2. Installation temperature


      1. When ambient temperature is below 15°C (59°F), perform the installation procedure after warming the vehicle body surface (installation surface of the door frame) and tape up to between 20 and 30°C (68 and 86°F) using a heat light. When ambient temperature is above 35°C (95°F), cool the vehicle body surface (installation surface of the door frame) and tape down to between 20 and 30°C (68 and 86°F) prior to installation.

        Tech Tips


        • The most appropriate temperature for installing the tape is 25°C (77°F).

        • When the temperature is low, the tape turns stiff and comes off easily. When the temperature is high, the tape looses elasticity.

    3. Before installation


      1. Remove any roughness of coating and dirt on and around the vehicle body surface where the tape will be installed (installation surface of the door frame). If any roughness or dirt remains when pressing the tape onto the surface, air will be trapped under the tape and result in a poor appearance.

        Tech Tips

        Spray water on the shop floor to settle any dust.

    4. Key points for handling the tape


      1. The tape bends and rolls up easily. Store the tape between flat pieces of cardboard or other similar objects and keep it dry and level.

        Note

        Do not bend the tape or leave it in high temperature places.

    5. Key points for installation of the tape (how to use a squeegee and installation procedure for flat surfaces)

      Note


      • Position the tape accurately to achieve a neat finish and to avoid peeling.

      • The tape cannot be reused because it deforms and will not fit any more after being removed.


      1. To avoid air bubbles, slightly raise the part of the tape that is going to be applied so that its adhesive surface does not touch the vehicle body while applying the tape. Tilt the squeegee at 40 to 50° (for pressing forward) or 30 to 45° (for pulling) to the vehicle body surface and press the tape onto the vehicle body surface with a force of 20 to 30 N (2 to 3 kgf) at a constant slow speed of 3 to 7 cm (1.2 to 2.8 in.) per second.

        A017FR0E02

        Note

        Be sure to observe the specified pressing speed, force, and angle of the squeegee to avoid wrinkles or air bubbles.

        Tech Tips


        • Either angle of the squeegee (for pressing forward or for pulling) is acceptable.

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.393 to 0.787 in.) from the edge of the squeegee.

    6. Key points for installation of the tape (how to use a squeegee and installation procedure for hemming surfaces)


      1. A017CMJE01

        If it is difficult to apply the tape, install it in several steps as shown in the illustration. Use your fingers or the padded surface of a squeegee to slowly apply the tape to the hem of the vehicle, especially for a small hem.

        Tech Tips

        When applying tape to the backside of a hem, remove the release paper and use your fingers or the padded surface of a squeegee.

    7. Key points for installation of the tape (how to use a squeegee and installation procedure for corners)


      1. Remove the release paper and apply the tape carefully with your fingers.

      2. Before applying the tape to each corner, heat the tape using a heat light and gradually apply it, avoiding wrinkles on the tape to achieve a neat finish.

    8. Check after installation


      1. After completing the application, check if the tape is applied neatly. If the tape is not applied neatly, reapply using new tape.

        Note

        Do not reuse the tape.

  2. INSTALL INNER REAR BLACK OUT REAR DOOR TAPE


    1. A017EKFE01

      Referring to the illustration, position the inner rear black out rear door tape.

    2. Remove the release paper and apply the tape.

  3. INSTALL INNER FRONT BLACK OUT REAR DOOR TAPE


    1. A017F4FE01

      Referring to the illustration, position the inner front black out rear door tape.

    2. Remove the release paper and apply the tape.

  4. INSTALL INNER UPPER BLACK OUT REAR DOOR TAPE


    1. A017GAPE01

      Referring to the illustration, position the inner upper black out rear door tape.

    2. Remove the release paper and apply the tape.

  5. INSTALL NO. 2 BLACK OUT TAPE


    1. A017DEDE01

      Referring to the illustration, position the No. 2 black out tape.

      Standard measurement
      Dimension Measurement
      A 2 to 4 mm (0.079 to 0.157 in.)
      B 4 to 6 mm (0.157 to 0.236 in.)

    2. Remove the release paper and apply the tape.

  6. INSTALL NO. 3 BLACK OUT TAPE


    1. A017C42E01

      Referring to the illustration, position the No. 3 black out tape.

      Standard measurement
      Dimension Measurement
      A 2 to 4 mm (0.079 to 0.157 in.)
      B 4 to 6 mm (0.157 to 0.236 in.)

    2. Remove the release paper and apply the tape.

  7. INSTALL REAR DOOR OUTSIDE MOULDING SUB-ASSEMBLY


    1. Clean the vehicle body surface.


      1. Using a heat light, heat the vehicle body surface.

      2. Remove the upper rear door outside moulding pad from the vehicle body.

      3. Wipe off any tape adhesive residue with cleaner.

    2. A017BC5E01

      Clean the rear door outside moulding sub-assembly. (If reusing the rear door outside moulding sub-assembly)


      1. Using a heat light, heat the rear door outside moulding sub-assembly.

      2. Remove the upper rear door outside moulding pad from the rear door outside moulding sub-assembly.

      3. Wipe off any tape adhesive residue with cleaner.

      4. Install a new upper rear door outside moulding pad to the rear door outside moulding sub-assembly.

    3. Install 2 new No. 3 clips on the rear door outside moulding sub-assembly.

    4. Install 6 new No. 4 clips on the rear door outside moulding sub-assembly.

    5. Install a new gasket on the rear door outside moulding sub-assembly.

    6. A017FXVE01

      Install the rear door outside moulding sub-assembly.


      1. Using a heat light, heat the vehicle body and rear door outside moulding sub-assembly.

      2. Remove the release paper from the rear door outside moulding sub-assembly.

        Tech Tips

        After removing the release paper, keep the exposed adhesive free from foreign matter.

      3. Engage the 8 clips and install the rear door outside moulding sub-assembly.

    7. A017EO5

      Install the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    8. Install the rear door No. 2 weatherstrip.

  8. INSTALL REAR DOOR NO. 2 WEATHERSTRIP


    1. A017FBM

      Engage the 11 clips and claw, and install the rear door No. 2 weatherstrip.

  9. INSTALL REAR DOOR BELT MOULDING ASSEMBLY


    1. A017CT3

      Engage the 6 claws and install the rear door belt moulding assembly.

  10. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


    1. Apply MP grease to the sliding parts on the rear door outside handle frame sub-assembly.

    2. A017E97

      Engage the 2 claws to install the rear door outside handle frame sub-assembly.

    3. Using a "TORX" socket wrench (T30), install the rear door outside handle frame sub-assembly with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  11. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A017CKK

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

  12. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A017BEC

      Engage the 3 claws to install the rear door front outside handle pad.

  13. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A017ERW

      Insert the front end of the rear door outside handle assembly into the rear door outside handle frame.

      Note

      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 may be damaged.

    2. Insert the rear end of the rear door outside handle assembly into the rear door outside handle frame. Next, slide the rear door outside handle assembly toward the front of the vehicle to install it.

  14. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A017CIQ

      Engage the claw to install the rear door outside handle cover.

    2. A017D6X

      Using a "TORX" socket wrench (T30), install the rear door outside handle cover with the screw.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  15. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY


    1. A017D8W

      Install the rear door inside locking cable assembly.

    2. A017EZ1

      Engage the 3 claws.

  16. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY


    1. A017EHD

      Install the rear door lock remote control cable assembly.

    2. A017FSJ

      Engage the claw.

  17. INSTALL REAR DOOR LOCK ASSEMBLY

    Note


    • 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.


    1. Apply MP grease to the sliding parts of the rear door lock assembly.

    2. Install a new door lock wiring harness seal to the rear door lock assembly.

    3. A017EWV

      Insert the rear door lock assembly to the rear door outside handle release plate, and set it to the rear door panel.

    4. Make sure that the rear door outside handle frame release plate is securely connected to the rear door lock assembly.

    5. Using a "TORX" socket wrench (T30), install the rear door lock assembly with the 3 screws.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  18. INSTALL REAR POWER WINDOW REGULATOR MOTOR ASSEMBLY

    Note

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


    1. A017ETW

      Using a "TORX" driver (T25), install the rear power window regulator motor assembly with the 3 screws.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Tech Tips

      A new rear window regulator uses self-tapping screws to thread new installation holes when the self-tapping screws are inserted.

    2. A017BW0E01

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

  19. INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSEMBLY


    1. Apply MP grease to the sliding parts of the rear door window regulator sub-assembly.

    2. A017B2YE02

      Install the temporary bolt to the rear door window regulator sub-assembly.

    3. Temporarily install the window regulator.

    4. Tighten the 4 bolts in the order shown in the illustration to install the rear door window regulator.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    5. Connect the connector.

  20. INSTALL REAR DOOR FRAME GARNISH


    1. A017EXJ

      Engage a new clip and install the rear door frame garnish.

  21. INSTALL REAR DOOR GLASS RUN


    1. A017BMF

      Install the rear door glass run.

  22. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A017B5Q

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

  23. INSTALL REAR DOOR QUARTER WINDOW GLASS


    1. Install the rear door quarter window glass to the rear door quarter window weatherstrip.

    2. A017G2W

      Install the rear door quarter window glass together with the rear door quarter window weatherstrip in the direction indicated by the arrow in the illustration.

  24. INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSEMBLY


    1. Insert the rear door window division bar sub-assembly from above.

    2. Install the rear door glass run to the rear door lower window frame sub-assembly.

    3. A017ECI

      Install the rear door window division bar sub-assembly with the 2 bolts and screw.

    4. A017FHT

      Install the rear door vent seal.

  25. INSTALL REAR DOOR WEATHERSTRIP


    1. A017B9B

      Engage the 19 clips and install the rear door weatherstrip.

  26. INSTALL REAR DOOR CHECK ASSEMBLY


    1. A017EAN

      Install the rear door check assembly with the bolt and 2 nuts.

      Torque:
      Bolt
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  27. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

    2. A017FALE01

      Pass the rear door lock remote control cable, rear door inside locking cable and each connector through a new rear door service hole cover.

    3. Attach the rear door service hole cover according to the reference points on the rear door panel.

      Note

      Securely install the rear door service hole cover avoiding wrinkles and air bubbles.

    4. Connect the connector.

  28. INSTALL REAR SPEAKER ASSEMBLY


    1. A017ESY

      Connect the connector.

    2. Install the rear speaker assembly with the 3 bolts.

      Note

      Do not touch the cone part of the speaker.

  29. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A017B79

      Install the rear door inner glass weatherstrip.

  30. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A017BNY

      Engage the 2 claws.

    2. Install the 2 screws and install the rear door inside handle sub-assembly.

  31. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. A017CXI

      Connect the rear door lock remote control cable and rear door inside locking cable to the rear door inside handle sub-assembly.

    2. Engage the 2 clamps.

    3. A017GAC

      Engage the rear door trim board with the 5 claws on the rear door inner glass weatherstrip.

    4. Engage the 9 clips and install the rear door trim board to the rear door panel.

    5. A017F2KE01

      Install the 2 screws <B>.

    6. Install the screw <A>.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  32. INSTALL DOOR ASSIST GRIP COVER


    1. A017C7J

      Engage the 4 claws and install the door assist grip cover.

  33. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY


    1. A017FQH

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

  34. INSTALL REAR DOOR ARMREST UPPER BASE PANEL


    1. Connect the connector.

    2. A017DAJ

      Engage the 6 claws and 2 clips and install the rear door armrest upper base panel.

  35. INSTALL REAR DOOR INSIDE HANDLE BEZEL PLUG


    1. A017ERK

      Engage the 3 claws to install the rear door inside handle bezel plug.

  36. CONNECT NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.