- removal without loops (when replacing a door);
- removal with loops (allows you to save the original settings)
Place the vehicle in the work area, disconnect the negative terminal from the battery (spanner 10), open the door and lower the sliding glass to the lower position.
Removal and installation
Open the back door.
Remove tube 3, Figure 4-1, the door wiring harness protective tube, and then the wiring harness from the hole in the body pillar.
Disconnect connector 2 of the door wiring harness from the connector of the rear wiring harness.
Figure 4-1 - Removing and installing the rear door: 1 - upper door hinge; 2 - door wiring harness connector; 3 - door wiring harness protective tube; 4 - door opening limiter; 5 - lower door hinge; 6 - bolt for fastening the door to the hinge link
Loosen the screw securing the 4th door limiter to the middle pillar of the body (torx T40 replaceable head, ratchet).
Unscrew bolts 6 securing the door to hinges 1 and 5, remove the door assembly (torx T40 replaceable head, ratchet or spanner 13).Perform the operation with an assistant.
Install the door in the reverse order of removal. When installing, ensure that the gaps with adjacent surfaces around the perimeter of the door are uniform.
Disassembly and assembly
For the version with manual window lift:
- remove cover 1, figure 4-2, window lift handles 2 from the door trim, remove retaining clip 3, remove handle (flat head screwdriver).
Figure 4-2 - Window lifter handle: 1 - window lift handle cover; 2 - window lift handle; 3 - window lift handle fixing bracket
Loosen screws 1, Figure 4-3, securing door trim 2 to the door panel (torx T20, T30 replaceable head, ratchet).
Overcoming the resistance of the holders, detach the trim from the door (flat head screwdriver).
Figure 4-3 - Rear door trim: 1 - upholstery mounting screw; 2 - rear door trim
Release the clamps of tip 1, figure 4-4, clip, cable 2 of the inner handle of the lock drive, disconnect the cable from the handle (flat head screwdriver).
Figure 4-4 - Disconnecting the lock drive rod: 1 - end of the inner handle cable clip of the lock drive; 2 - cable of the inner handle of the lock drive
Remove holder 2, figure 4-5, door trim (flat head screwdriver).
Remove the sealing film 1, if necessary use a burner with hot air supply to the place where the mastic is applied (technological knife).
Figure 4-5 - Door cavity sealing film: 1 - sealing film; 2 - upholstery holder
Note: The sealing film is replaceable.
Remove seal 1 from the end of the front part of the door frame, Figure 4-6.
Grasp the edge of the outer horizontal door glass seal and pull it upward to remove it from the door panel.
Remove seal 2 from the window frame.
Figure 4-6 - Door hardware: 1 - front vertical door frame seal; 2 - seal of the frame of the lowering glass; 3 - cable of the inner door lock drive handle; 4 - door wiring harness; 5 - door lock mounting screw; 6 - window regulator mounting nut; 7 - door opening limiter; 8 - window lifter; 19 - nut for fastening the sliding glass guide; 10 - glass fastening axis; 11 - glass retainer; 12 - loudspeaker mounting rivets; 13 - glass
Raise the door glass until the unit 14 connecting the glass 13 to the window lifter 8 appears in the opening of the inner door panel.
In the door cavity, from the side of the door front panel, remove the glass retainer 11 from the axis 10 of the glass fastening to the glass lifter.
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Remove the glass from the window lifter shaft and take it out of the door cavity.
Unscrew the nuts 6 securing the window regulator, remove the window regulator from the door cavity (replacement head 10, ratchet).
Unscrew nuts 9 securing the drop glass guide, remove the guide from the door cavity (replacement head 10, ratchet).
Loosen screws 5, fastening the lock to the door, remove the lock from the door cavity together with the cable of the inner door handle (torx T30 replaceable head, ratchet).
Disconnect the door wiring harness connector and the inner handle cable from the lock (flat head screwdriver).
Loosen the screw securing the limiter 4, see Figure 3-8, the door to the body pillar (torx T40 replaceable head, ratchet).
Remove seal 3 of limiter 2 from the end of the door panel, unscrew nuts 1 securing the limiter to the door, remove the limiter (replacement head 10, ratchet, flat screwdriver).
Disconnect the door wiring harness connector from the speaker, the harness attachment points to the door panel and remove the harness from the door cavity.
Loosen screws 3, Figure 4-7, securing decorative trim 2 to the rear part of door frame 1, remove trim (torx T20 replaceable head, ratchet, extension).
Figure 4-7 - Rear Door Frame Trim: 1 - rear door; 2 - overlay; 3 - screw for fixing the lining
Remove the plug from hole 1, Figure 4-8, at the end of the door and through the opened hole unscrew the screw securing the decorative plug 2 of the outer handle 3, remove the plug (flat screwdriver, replaceable Torx T20 head, ratchet, extension).
Figure 4-8 - External door handle: 1 - hole for the screw fixing the plug of the outer door handle; 2 - outer handle plug; 3 - external door handle
To remove the outer door lock handle, grasp the handle and without pulling it, move it back, then in the moved position, pull the rear part of the handle until the rear hook comes out of the hole in the door panel and, pulling the handle with a force that overcomes the force of the hinge lock of the front part of the handle, remove the handle, see Figure 3-9.
The outer handle mechanism, the upper guide of the drop glass, and the loudspeaker are attached to the door with rivets, Figure 4-9.
Figure 4-9 - Fastening the rear door parts with rivets: 1 - rivet
Dismantling of these parts must be carried out carefully, without damaging the paintwork, by drilling out the fastening rivet (drill, ∅ 5 mm drill).
Assemble the door units and parts in the reverse order of disassembly, while:
- lubricate the rubbing parts of the window lifter, sliding surfaces in the door lock, door opening limiter, rod joints and hinges (grease type TSIA-TIM-201, consumption rate - 5 g);
- when installing the external handle, ensure that the return mechanism lever is captured by the handle hook, as shown in Figure 3-10;
- before installing the door trim, temporarily install the window lift handle or switch, connect the negative terminal to the battery, check and, if necessary, adjust the operation of the door lock and window lift; raise the window, disconnect the negative terminal from the battery and remove the window handle or switch.
The door fittings and components must be secured to all attachment points provided by the design.
When installing the housing of the return mechanism of the external handle and the loudspeaker, it is permissible to use alternative fasteners of the appropriate diameter.
Present the vehicle to the Quality Control Department. The Quality Control Department will check the vehicle for compliance with the following requirements: the doors of the body must open and close easily, spontaneous opening of the doors is not allowed; when the door locks are locked, the latter should not be opened by the outside handles; window lift mechanisms must ensure uniform, jam-free, full reversible movement of the vehicle's lowering windows.