Rear Door Reassembly

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)

   NOTICE:

   Do not heat the vehicle body excessively.

2. Wipe off any tape adhesive residue with cleaner.
   

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.
   

   HINT:

   1. The most appropriate temperature for installing the tape is 25°C (77°F).
      
   2. When the temperature is low, the tape turns stiff and falls off easily. When the temperature is high, the tape loses elasticity.
      

Before installation

1. Remove any coating roughness 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.
   

   HINT:

   Spray water on the shop floor to settle any dust.

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.
   

   NOTICE:

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

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

NOTICE:

1. Conduct positioning of the tape with a high level of accuracy to achieve a neat finish and to avoid peeling.
   
2. 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 (1.18 to 2.76 in.) per second.
   
   

   
   
   
   

   NOTICE:

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

   HINT:

   1. Either angle of the squeegee (for pressing forward or for pulling) is acceptable.
      
   2. 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.
      

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

1. If it is difficult to press the tape, press 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.
   

   HINT:

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

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 to avoid wrinkles on the tape and achieve a neat finish.
   

Check after installation

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

   NOTICE:

   Do not reuse the tape.

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

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

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

Engage the 2 claws (B).

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

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

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

Torque:

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

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

NOTICE:

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.

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.

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

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}

Install the rear door inside locking cable assembly.

Install the rear door inside locking cable assembly.

Engage the 3 claws.

Install the rear door lock remote control cable assembly.

Install the rear door lock remote control cable assembly.

Engage the claw.

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

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

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

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}

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

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

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

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

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}

Connect the connector.

Clean the rear door panel sub-assembly.

Engage the guide.

Install a new separator door No. 2 stiffener cushion with the bolt.

Torque:

6.2 N*m{63 kgf*cm, 55 in.*lbf}

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

Torque:

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

HINT:

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

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

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

Install the rear door window regulator assembly with the 3 bolts.

Torque:

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

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

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

Temporarily install the rear door window regulator sub-assembly.

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

Torque:

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

Connect the connector.

Install a new rear door frame garnish with the clip.

Install the rear door glass run.

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

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

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.

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

Install the rear door glass run to the rear door window division bar sub-assembly.

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

Torque:

6.2 N*m{63 kgf*cm, 55 in.*lbf}

Engage the 15 clips and install the rear door weatherstrip.

Install the rear door check assembly with the 3 bolts.

Torque:

Bolt (1):

30 N*m{306 kgf*cm, 22 ft.*lbf}

Bolt (2):

5.5 N*m{56 kgf*cm, 49 in.*lbf}

Apply butyl tape to the rear door panel.

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

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

NOTICE:

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

w/ Power door lock:

1. Connect the connector.
   

Install the rear door trim bracket with the 2 screws.

Install the rear door inner glass weatherstrip.

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

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

Engage the rear door trim board with the 4 claws on the rear door inner glass weatherstrip.

Engage the 8 clips to install the rear door trim board to the rear door panel.

Install the 2 screws.

Engage the claw to install the door armrest cap.

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

Engage the 2 clips and 7 claws, and install the rear door armrest upper base panel.

Connect the connector.

Engage the 2 clips and 7 claws, and install the rear door armrest upper base panel.

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

Temporarily install the rear door window regulator handle assembly and fully close the window glass.

Install the rear door regulator inside handle plate.

Install the snap ring to the rear door window regulator handle assembly.

Install the rear door window regulator handle assembly as shown in the illustration.