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 falls off easily. When the temperature is high, the tape loses 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° (pressing forward) or 30 to 45° (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, 4.5 to 6.7 lbf) at a constant slow speed of 3 to 7 cm (1.18 to 2.76 in.) per second.

        A003SLVE02
        Text in Illustration
        *A Pressing Forward *B Pulling
        *1 Non-padded Side *2 Padded Side
        *3 Squeegee *4 Black Out Tape
        *5 Release Paper - -
        *a Side View - -

        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 (pressing forward or pulling) is acceptable.

        • Be sure to apply the tape while removing the release paper 10 to 20 mm (0.394 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 hemmed surfaces)


      1. A003TU3E09
        Text in Illustration
        *1 Squeegee
        *2 Hem
        *a First
        *b Second
        *c Third

        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 NO. 3 BLACK OUT TAPE


    1. A003RYVE01

      Refer to the illustration to position the No. 3 black out tape.

      Reference measurement
      Area Measurement
      A 2 to 4 mm (0.078 to 0.158 in.)
      B 5 mm (0.197 in.)

    2. Remove the release paper and apply the tape.

  3. INSTALL REAR DOOR PANEL CUSHION


    1. A003UGW

      Engage the 4 claws and install 2 new rear door panel cushions.

  4. INSTALL REAR DOOR BELT MOULDING ASSEMBLY


    1. Engage the 6 claws and 2 clips, and install the rear door belt moulding assembly.

  5. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSEMBLY


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

    2. A003RJ5E01

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

    3. Engage the 2 claws (B).

  6. INSTALL REAR DOOR REAR OUTSIDE HANDLE PAD


    1. A003SNI

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

  7. INSTALL REAR DOOR FRONT OUTSIDE HANDLE PAD


    1. A003SWF

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

    2. A003S2J

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

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

  8. INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY


    1. A003SVO

      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 will 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.

  9. INSTALL REAR DOOR OUTSIDE HANDLE COVER


    1. A003SH2

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

    2. A003TDW

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

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

  10. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/o Double Locking System)


    1. A003S4T

      Install the rear door inside locking cable assembly.

    2. A003TYX

      Engage the 3 claws.

  11. INSTALL REAR DOOR INSIDE LOCKING CABLE ASSEMBLY (w/ Double Locking System)


    1. A003STQ

      Install the rear door inside locking cable assembly.

    2. A003RY2

      Engage the 3 claws.

  12. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/o Double Locking System)


    1. A003S9C

      Install the rear door lock remote control cable assembly.

    2. A003TVL

      Engage the claw.

  13. INSTALL REAR DOOR LOCK REMOTE CONTROL CABLE ASSEMBLY (w/ Double Locking System)


    1. A003UTR

      Install the rear door lock remote control cable assembly.

    2. A003U0P

      Engage the claw.

  14. 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. A003S44

      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 T30 "TORX" socket wrench, install the rear door lock assembly with the 3 screws.

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

  15. INSTALL REAR DOOR WINDOW REGULATOR ASSEMBLY


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

    2. A003ROYE02
      Text in Illustration
      *1 Temporary Bolt

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

    3. Temporarily install the rear door window regulator assembly.

    4. Tighten the temporary bolt and 3 bolts to install the rear door window regulator assembly.

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

    5. Connect the connector.

  16. INSTALL REAR DOOR FRAME GARNISH


    1. A003UAM

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

  17. INSTALL REAR DOOR GLASS RUN


    1. A003TZP

      Install the rear door glass run.

  18. INSTALL REAR DOOR GLASS SUB-ASSEMBLY


    1. A003TJS

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

  19. INSTALL REAR DOOR QUARTER WINDOW GLASS


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

    2. A003SID

      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.

  20. 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 window division bar sub-assembly.

    3. A003TOO

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

  21. INSTALL REAR DOOR WEATHERSTRIP


    1. A003UDA

      Engage the 16 clips and install the rear door weatherstrip.

  22. INSTALL REAR DOOR CHECK ASSEMBLY


    1. A003SA6

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

      Torque:
      Bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      Nut
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  23. INSTALL REAR DOOR SERVICE HOLE COVER


    1. Apply butyl tape to the rear door panel.

    2. A003SZCE02
      Text in Illustration
      *1 Reference Point

      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 by using 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.

  24. INSTALL REAR SPEAKER ASSEMBLY


    1. Using an air riveter or hand riveter, install the rear speaker assembly with 3 new rivets.

      A003U92E02
      Text in Illustration
      *1 Riveter *2 Mandrel
      *a INCORRECT - -

      Note


      • Do not pry the rivet with the riveter, as this will cause damage to the riveter and mandrel.

      • Confirm that the rivet is seated properly against the moulding. Do not tilt the riveter when installing the rivet to the moulding. Do not leave any space between the rivet head and moulding.

      • Do not leave any space between the moulding and door frame. Firmly hold the 2 items together while installing the rivet.

      Tech Tips

      If the rivet cannot be cut, pull it once and cut it.

    2. A003T5X

      Connect the connector.

  25. INSTALL REAR DOOR INNER GLASS WEATHERSTRIP


    1. A003SL7

      Install the rear door inner glass weatherstrip.

  26. INSTALL REAR POWER WINDOW REGULATOR SWITCH ASSEMBLY


    1. A003TZL

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

  27. INSTALL SWITCH BEZEL


    1. A003TL6

      Engage the 4 claws and install the switch bezel.

  28. INSTALL REAR DOOR INSIDE HANDLE SUB-ASSEMBLY


    1. A003T8I

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

    2. A003SUF

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

  29. INSTALL REAR DOOR TRIM BOARD SUB-ASSEMBLY


    1. Connect the connector.

    2. A003UCF

      Engage the rear door trim board with the 3 claws on the rear door inner glass weatherstrip.

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

    4. A003RKD

      Install the 3 screws.

  30. INSTALL DOOR ASSIST GRIP COVER


    1. A003SRH

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

  31. INSTALL REAR DOOR INSIDE HANDLE BEZEL


    1. A003SOG

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

  32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  33. INSTALL BATTERY BOX COVER


    1. Engage the 3 guides to install the battery box cover.

  34. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  35. INSTALL REAR FLOOR MAT


    1. Install the rear floor mat.

  36. INITIALIZE POWER WINDOW CONTROL SYSTEM

    Click here