Engine Hood/door: Overhaul Lexus GX J120

OVERHAUL

HINT

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.

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1. REMOVE RADIATOR GRILLE Remove the 2 bolts and auxiliary catch release lever assy. Remove the bolt and auxiliary catch hook assy. Remove the 8 nuts and radiator grille.
2. REMOVE HOOD INSULATOR Using a clip remover, remove the 11 clips and hood insulator.
3. REMOVE HOOD SUPPORT ASSY LH (See «REPLACEMENT»(ref-228811-S38418019262006041100000) )
4. REMOVE HOOD SUPPORT ASSY RH (See «REPLACEMENT»(ref-228811-S38418019262006041100000) )
5. REMOVE HOOD SUB-ASSY Remove the 4 bolts and hood sub-assy.
6. REMOVE HOOD HINGE ASSY LH Remove the 2 bolts and hood hinge assy.
7. REMOVE HOOD HINGE ASSY RH Remove the 2 bolts and hood hinge assy.
8. REMOVE RADIATOR SUPPORT SEAL UPPER Using a clip remover, remove the 8 clips and support seal upper.
9. REMOVE HOOD LOCK ASSY Using a screwdriver, disengage the 4 clips, and remove the hood lock release lever protector. HINT: Tape the screwdriver tip before use. NOTE: Removing the protector damages the clips inside the protector. Therefore the use of a new protector is necessary on the installation. Remove the 3 bolts and hood lock assy. Disconnect the connector.
10. INSTALL HOOD LOCK ASSY Connect the connector. Install the hood lock with the 3 bolts. Adjust the hood lock position (See «ADJUSTMENT»(ref-228811-S37533730782006041100000) ). Install the protector.
11. INSTALL HOOD HINGE ASSY LH Install the hood hinge assy with the 2 bolts. Torque: 13.0 N.m (130 kgf.cm, 10 ft.lbf)
12. INSTALL HOOD HINGE ASSY RH Install the hood hinge assy with the 2 bolts. Torque: 13.0 N.m (130 kgf.cm, 10 ft.lbf)
13. INSTALL HOOD SUB-ASSY Install the hood sub-assy with the 4 bolts. Torque: 13.0 N.m (130 kgf.cm, 10 ft.lbf)
14. INSTALL RADIATOR GRILLE Install the radiator grille with the 8 nuts. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) Install the auxiliary catch hook assy with the bolt. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) Install the auxiliary catch release lever assy with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)

HINT

1. The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
2. On the RH side, use the same procedures as on the LH side.

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1. REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH Using a screwdriver, disengage the clip and claw, and remove the lower frame bracket garnish. HINT: Tape the screwdriver tip before use.
2. REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH Using a screwdriver, disengage the 3 claws and remove the inside handle bezel. HINT: Tape the screwdriver tip before use.
3. REMOVE FRONT ARMREST ASSY LH Using a screwdriver, disengage the 2 claws and 2 clips, and then remove the armrest assy from the trim board sub-assy. HINT: Tape the screwdriver tip before use.
4. REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY Using a screwdriver, disengage the 2 claws and 2 clips, and then remove the armrest base panel upper together with the master switch assy. HINT: Tape the screwdriver tip before use. Disconnect the master switch connector. Remove the 3 screws and the master switch from the armrest base panel upper.
5. REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH Remove the 2 cushion rubbers. Remove the 3 screws and the clip indicated. Using a clip remover, disengage the other 10 clips. Remove the trim board sub-assy upward. HINT: In order to prevent the door panel from being damaged, cover the parts indicated by arrow marks in (Scheme 184) with tape. Disconnect the 2 speaker connectors. Disconnect the 2 cables from the inside handle (Scheme 185) Remove the inner weatherstrip. Remove the No. 2 speaker (See «FRONT NO. 2 SPEAKER ASSY»(ref-228804-S02916972412006041100000) ). Remove the stereo component speaker (See «STEREO COMPONENT SPEAKER ASSY»(ref-228804-S18232601072006041100000) ). Remove the 2 screws and the inside handle sub-assy. Using a screwdriver, disengage the claw and remove the illumination lamp assy (Scheme 186) HINT: Tape the screwdriver tip before use.
6. REMOVE FRONT DOOR SERVICE HOLE COVER LH NOTE: Remove the remaining tape on the door side.
7. REMOVE OUTER REAR VIEW MIRROR ASSY LH Disconnect the mirror connector. Remove the 3 nuts and outer rear view mirror assy. NOTE: When the nuts are removed, the outer rear view mirror assy may fall and become deformed.
8. REMOVE FRONT NO. 2 SPEAKER ASSY (SEE «FRONT NO. 2 SPEAKER ASSY»(ref-228804-S02916972412006041100000) )
9. REMOVE FRONT DOOR WINDOW FRAME MOLDING REAR LH (SEE «FRONT DOOR WINDOW FRAME MOLDING REAR LH»(ref-228812-S16011073462006041100000) )
10. REMOVE FRONT DOOR BELT MOLDING LH (SEE «FRONT DOOR BELT MOLDING LH»(ref-228812-S39560106302006041100000) )
11. REMOVE FRONT DOOR GLASS SUB-ASSY LH HINT: Insert a shop rag inside the door panel to prevent the door glass sub-assy from being scratched. Open the door glass until the bolts appear in the service holes. Remove the 2 bolts holding the door glass sub-assy to the window regulator sub-assy. Remove the door glass sub-assy (Scheme 190) NOTE: Do not damage the door glass sub-assy. When the bolts are removed, the door glass sub-assy may fall and become deformed. Remove the glass run.
12. REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH Disconnect the window regulator connector. Remove the 6 bolts and window regulator sub-assy. NOTE: When the bolts are removed, the window regulator sub-assy may fall and become deformed. HINT: Remove the window regulator sub-assy through the service hole.
13. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH Place matchmarks on the regulator motor gear and regulator gear. Using a torx(R) driver (T25), remove the 3 screws and window regulator motor assy.
14. REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH Remove the bolt and frame sub-assy.
15. REMOVE FRONT DOOR OUTSIDE HANDLE COVER LH Remove the hole plug. Using a torx(R) socket wrench (T30), loosen the screw and remove the outside handle cover with the door lock key cylinder installed.
16. REMOVE FRONT DOOR W/MOTOR LOCK ASSY LH Disconnect the door lock connector. Using a torx(R) socket wrench (T30), remove the 3 screws and door lock assy. HINT: Remove the door lock assy through the service hole.
17. REMOVE FRONT DOOR HANDLE ASSY OUTSIDE LH Pushing and pulling the outside handle assy in the direction of the arrow mark (Scheme 195), remove the outside handle. Remove the outside handle pads front and rear.
18. REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH Using a torx(R) socket wrench (T30), loosen the screw. Slide the outside handle frame sub-assy to remove it. HINT: Remove the outside handle frame sub-assy through the service hole. Remove the lock open rod from the outside handle frame sub-assy.
19. REMOVE FRONT DOOR CHECK ASSY LH Remove the check cover. Remove the 2 nuts, bolt and door check assy.
20. REMOVE FRONT DOOR WEATHERSTRIP LH Using a clip remover, disengage the clips, and remove the weatherstrip. HINT: If the clips are damaged, exchange them for new ones.
21. REMOVE FRONT DOOR WIRE LH Disconnect the wire clips. Remove the 2 bolts and door wire.
22. INSTALL FRONT DOOR WIRE LH Install the door wire with the 2 bolts. Torque (reference): 8.0 N.m (82 kgf.cm, 71 in.lbf) NOTE: In order to prevent water leakage, be sure that the lip of the rubber grommet does not turn up or is not deformed when installing the door wire. Connect the wire clips.
23. INSTALL FRONT DOOR CHECK ASSY LH Apply MP grease to the sliding parts of the door check assy. Install the door check assy to the door panel with the 2 nuts. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) HINT: Install the door check assy so that the rivet head is up. Apply adhesive to the threads of the bolt. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the door check assy to the body with the bolt. Torque: 30 N.m (306 kgf.cm, 22 in.lbf) Install the check cover.
24. INSTALL FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH Install the lock open rod to the outside handle frame sub-assy. Using a torx(R) socket wrench (T30), install the outside handle frame sub-assy with the screw. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) NOTE: A cover should be inserted between the nut and the door panel. Install the outside handle pads front and rear.
25. INSTALL FRONT DOOR HANDLE ASSY OUTSIDE LH Pushing the outside handle assy in the direction of the arrow mark (Scheme 202), install the outside handle assy. NOTE: If the release plate is not pulled and held when installing the outside handle assy, the release plate will interfere with the outside handle assy, and damage the release plate.
26. INSTALL FRONT DOOR W/MOTOR LOCK ASSY LH Apply MP grease to the sliding and rotating parts of the door lock assy. If reusing the door lock assy: Install a new door lock wire harness packing. NOTE: If reusing a door lock assy that has been removed, replace the packing in the connecting part with a new one. Be careful that no grease and dirt sticks to the packing surface in the connecting part. Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock assy. Insert the door lock open rod into the door lock assy, and then set it to the door panel. NOTE: Make sure that the outside handle link is securely engaged with the door lock assy. Apply adhesive to the threads of the screws. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using a torx(R) socket wrench (T30), install the door lock assy with the 3 screws. Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf) Connect the door lock connector.
27. INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH Using a torx(R) socket wrench (T30), install the outside handle cover with the screw. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) Install the hole plug.
28. INSTALL FRONT DOOR FRAME SUB-ASSY REAR LOWER LH Install the door frame sub-assy with the bolt. Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)
29. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH Align the matchmarks on the regulator motor gear and regulator gear. Using a torx(R) driver (T25), install the regulator motor assy with the 3 screws. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) HINT: Never rotate the motor assy in the down direction until the window glass installation is done.
30. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH Apply MP grease to the sliding and rotating parts of the window regulator sub-assy. NOTE: Do not apply grease to the spring of the window regulator sub-assy. Install the window regulator sub-assy with the 6 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) Connect the window regulator connector. NOTE: Be careful not to drop and deform the door window regulator sub-assy as this may cause deformation.
31. INSTALL FRONT DOOR GLASS SUB-ASSY LH NOTE: Do not damage the door glass sub-assy. Install the glass run. Insert the door glass sub-assy into the door panel along the glass run (Scheme 209) Install the door glass sub-assy to the window regulator sub-assy with the 2 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) Inspect operation of the power window. HINT: When the installation point of the door glass sub-assy does not match, adjust the regulator position in manual operation. Connect the power window switch to the wire harness and turn the ignition switch ON. Repeat UP and DOWN operation several times in manual operation.
32. INSTALL OUTER REAR VIEW MIRROR ASSY LH Install the outer rear view mirror assy with the 3 nuts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) Connect the outer mirror connector.
33. INSTALL FRONT DOOR SERVICE HOLE COVER LH Apply butyl tape to the door panel (Scheme 212) Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent Install the service hole cover. Dimensions: DIMENSION SPECIFICATION A 6.0 mm (0.236 in.) B 2.0 mm (0.079 in.) HINT: When installing the service hole cover, pull out the links and connectors through the service hole cover. There should be no wrinkles or folds after attaching the service hole cover. After attaching the service hole cover, confirm the sealing condition.

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HINT

1. The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.
2. On the RH side, use the same procedures as on the LH side.

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1. REMOVE REAR DOOR INSIDE HANDLE BEZEL LH Using a screwdriver, disengage the 3 claws and remove the inside handle bezel. HINT: Tape the screwdriver tip before use.
2. REMOVE REAR LH ARMREST ASSY Using a screwdriver, disengage the 2 claws and 2 clips, and remove the armrest assy. HINT: Tape the screwdriver tip before use.
3. REMOVE POWER WINDOW REGULATOR SWITCH ASSY REAR Remove the rear ash receptacle assy. Using a screwdriver, disengage the 2 claws and 2 clips, and remove the armrest base panel upper together with the window switch assy. HINT: Tape the screwdriver tip before use. Disconnect the power window switch connector. Using a screwdriver, disengage the 2 claws, and then remove the switch assy from the base panel upper. HINT: Tape the screwdriver tip before use.
4. REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH Remove the 2 cushion rubbers. Remove the 3 screws. Using a clip remover, remove the 8 clips and remove the trim board sub-assy upward. HINT: In order to prevent the door panel from being damaged, cover the parts indicated by arrow marks in (Scheme 218) with tape. Disconnect the 2 cables from the inside handle sub-assy (Scheme 219) Remove the weatherstrip inner. Remove the 2 screws and inside handle sub-assy.
5. REMOVE REAR DOOR SERVICE HOLE COVER LH Remove the cover. NOTE: Remove the remaining tape on the door side. Using a screwdriver, remove the 2 screws and trim bracket.
6. REMOVE REAR SPEAKER ASSY (SEE «REAR SPEAKER ASSY»(ref-228804-S15190674232006041100000) )
7. REMOVE REAR DOOR WINDOW FRAME MOLDING FRONT LH (SEE «REAR DOOR WINDOW FRAME MOLDING FRONT LH»(ref-228812-S17269820162006041100000) )
8. REMOVE REAR DOOR BELT MOLDING LH (SEE «REAR DOOR BELT MOLDING LH»(ref-228812-S09996537492006041100000) )
9. REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH HINT: Insert a shop rag inside the door panel to prevent the glass from being scratched. NOTE: Do not damage the door glass. Remove the glass run. Remove the 2 bolts, screw and division bar. Rotate the division bar sub-assy by 90° and pull it upward (Scheme 222)
10. REMOVE REAR DOOR QUARTER WINDOW GLASS LH Remove the quarter window glass (Scheme 223) NOTE: Do not damage the glass. Remove the quarter window weatherstrip from the glass.
11. REMOVE REAR DOOR GLASS SUB-ASSY LH Carefully pull up the door glass sub-assy out of the door panel. HINT: Insert a shop rag inside the door panel to prevent the door glass sub-assy from being scratched.
12. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY LH Disconnect the window regulator connector. Remove the 4 bolts and window regulator sub-assy. NOTE: When the bolts are removed, the window regulator sub-assy may fall and become deformed. HINT: Remove the window regulator sub-assy through the service hole.
13. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH Place matchmarks on the regulator motor gear and regulator gear. Using a torx(R) driver (T25), remove the 3 screws and regulator motor assy.
14. REMOVE REAR DOOR W/MOTOR LOCK ASSY LH Disconnect the door lock connector. Using a torx(R) socket wrench (T30), remove the 3 screws and door lock assy. HINT: Remove the door lock assy through the service hole.
15. REMOVE REAR DOOR OUTSIDE HANDLE COVER LH Using a torx(R) socket wrench (T30), loosen the screw and remove the outside handle cover.
16. REMOVE REAR DOOR OUTSIDE HANDLE ASSY LH Pull and hold the release plate of the outside handle frame assy (Scheme 226) Pushing and pulling the outside handle assy in the direction of the arrow mark (Scheme 227), remove the outside handle assy. NOTE: If the release plate is not pulled and held when removing the outside handle assy, the release plate will interfere with the outside handle. It will damage the release plate. Remove the outside handle pads front and rear.
17. REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH Using a torx(R) socket wrench (T30), loosen the screw. Slide the outside handle frame sub-assy to remove it. HINT: Remove the outside handle frame sub-assy through the service hole.
18. REMOVE REAR DOOR CHECK ASSY LH Remove the check cover. Remove the 2 nuts, bolt and door check assy. HINT: Remove the door check assy through the service hole.
19. REMOVE REAR DOOR WEATHERSTRIP LH Using a clip remover, disengage the clip, and remove the weatherstrip. HINT: If the clip is damaged. exchange it for new one.
20. INSTALL REAR DOOR CHECK ASSY LH Apply MP grease to the sliding and rotating parts of the door check assy. Install the door check assy to the door panel with the 2 nuts. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) HINT: Install the door check assy so that the rivet head is up. Apply adhesive to the threads of the bolt. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the door check assy to the body panel with the bolt. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) Install the check cover. INSTALL REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH Using a torx(R) socket wrench (T30), install the handle frame sub-assy with the screw. Torque: 7.0 N.m (56 kgf.cm, 49 in.lbf) NOTE: A cover should be inserted between the nut and the door panel. Install the outside handle pads front and rear. INSTALL REAR DOOR OUTSIDE HANDLE ASSY LH Pull and hold the release plate of the outside handle frame sub-assy (Scheme 232) Pushing the outside handle assy in the direction of the arrow marks (Scheme 233), install the outside handle assy. NOTE: If the release plate is not pulled and held when installing the outside handle assy, the release plate will interfere with the outside handle assy. It will damage the release plate. INSTALL REAR DOOR OUTSIDE HANDLE COVER LH Using a torx(R) socket wrench (T30), install the outside handle cover with the screw. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) INSTALL REAR DOOR W/MOTOR LOCK ASSY LH Apply MP grease to the sliding and rotating parts of the door lock assy. If reusing the door lock assy: Install a new door lock wire harness packing. NOTE: If reusing a removed door lock assy, replace the packing in the connecting part with a new one. Be careful that no grease and dirt sticks to the packing surface in the connecting part. Reusing the packing or using a damaged packing will cause allow water to penetrate through the connecting part, resulting in a malfunction of the door lock. Engage the door assy with the release plate of the outside handle sub-assy, and then set it to the door panel. NOTE: Make sure that the release plate of the outside handle frame sub-assy is securely engaged with the door lock assy. Apply adhesive to the threads of the screws. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using a torx(R) socket wrench (T30), install the door lock assy with the 3 screws. Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf) Connect the door lock connector. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH Using a torx(R) driver (T25), install the regulator motor assy with the 3 screws. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSY LH Apply MP grease to the sliding and rotating parts of the window regulator sub-assy. NOTE: Do not apply grease to the spring of the window regulator sub-assy. Install the window regulator sub-assy with the 4 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) NOTE: Be careful not to drop the rear door window regulator sub-assy, as this may cause deformation. Connect the window regulator connector. INSTALL REAR DOOR GLASS SUB-ASSY LH NOTE: Be careful not to drop the glass sub-assy, as this may cause deformation. Install the door glass sub-assy into the door panel. HINT: Insert a shop rag inside the door panel to prevent the door glass sub-assy from being scratched. INSTALL REAR DOOR QUARTER WINDOW GLASS LH Install the quarter window weatherstrip on the glass. NOTE: Do not damage the glass. Install the quarter window glass (Scheme 237) INSTALL REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH Insert the division bar sub-assy into the door panel, then rotate it by 90° (Scheme 238) Mount the door glass sub-assy to the window regulator sub-assy. Tighten the division bar sub-assy with the 2 bolts and screw. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf) Install the glass run. Inspect operation of the power window. HINT: When the installation point of the door glass does not match, adjust the window regulator position in manual operation. Connect the power window switch to the wire harness and turn the ignition switch ON. Repeat UP and DOWN operation several times in manual operation.
21. INSTALL REAR DOOR SERVICE HOLE COVER LH Apply butyl tape to the door panel (Scheme 240) Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent Install the service hole cover. Dimensions: HINT: When installing the service hole cover, pull out the links and connectors through the service hole cover. There should be no wrinkles or folds after attaching the service hole cover. After attaching the service hole cover, confirm the sealing condition.

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HINT

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.

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1. REMOVE BACK DOOR GARNISH CENTER Using a clip remover, disengage the 5 clips, and remove the garnish center.
2. REMOVE BACK DOOR SIDE GARNISH LH Using a clip remover, disengage the 3 clips, and remove the side garnish.
3. REMOVE BACK DOOR SIDE GARNISH RH Using a clip remover, disengage the 3 clips, and remove the side garnish.
4. REMOVE TOOL BOX PANEL SUB-ASSY UPPER Remove the tool cover and tool set.
5. REMOVE ASSIST GRIP ASSY Remove the 2 assist grip covers and assist grip assy.
6. REMOVE BACK DOOR TRIM BOARD Remove the 2 trim board covers. Remove the screw. Using a screwdriver, disengage the 15 clips and remove the trim board. HINT: Tape the screwdriver tip before use. Remove the 7 screws and trim pocket. w/ Speaker Remove the 4 screws and rear speaker grille sub-assy LH and RH.
7. REMOVE BACK DOOR STOPPER LOWER Remove the packing. Using a screwdriver, disengage the claw, and remove the stopper lower.
8. REMOVE BACK DOOR SERVICE HOLE COVER NOTE: Remove the remaining tape on the door side.
9. REMOVE STEREO COMPONENT SPEAKER ASSY (W/ SPEAKER) (SEE «STEREO COMPONENT SPEAKER ASSY»(ref-228804-S18232601072006041100000) )
10. REMOVE BACK DOOR OUTSIDE HANDLE Remove the 2 bolts and outside handle. Remove the cable. HINT: Remove the outside handle through the service hole.
11. REMOVE W/MOTOR BACK DOOR LOCK ASSY Disconnect the door lock connector. Using a torx(R) socket wrench (T30), remove the 3 screws and door lock assy. HINT: Remove the door lock assy through the service hole.
12. REMOVE LICENSE REAR LAMP COVER (SEE «BACK DOOR GARNISH SUB-ASSY OUTSIDE»(ref-228812-S39805326622006041100000) )
13. REMOVE BACK DOOR GARNISH SUB-ASSY OUTSIDE (SEE «BACK DOOR GARNISH SUB-ASSY OUTSIDE»(ref-228812-S39805326622006041100000) )
14. REMOVE REAR WIPER MOTOR ASSY (SEE «REAR WIPER MOTOR ASSY»(ref-228803-S13893101622006041100000) )
15. REMOVE BACK DOOR SIDE FEMALE STOPPER SUB-ASSY RH Remove the 2 bolts and female stopper sub-assy.
16. REMOVE BACK DOOR LINK SUB-ASSY LOWER Remove the top set bolt cap B. Remove the bolt and back door link sub-assy.
17. REMOVE BACK DOOR STAY RAIL SUB-ASSY RH Remove the 2 bolts and stay rail sub-assy.
18. REMOVE REAR BUMPER COVER (SEE «REPLACEMENT»(ref-228812-S24027799102006041100000) )
19. REMOVE BACK DOOR STAY BRACKET SUB-ASSY RH Remove the 2 bolts and stay bracket sub-assy.
20. INSTALL BACK DOOR STAY BRACKET SUB-ASSY RH Install the back door stay bracket sub-assy with the 2 bolts. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
21. INSTALL BACK DOOR STAY RAIL SUB-ASSY RH Apply MP grease to the sliding parts of the stay rail sub-assy (Scheme 249) Install the stay rail sub-assy with the 2 bolts. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) Install the top set bolt cap B.
22. INSTALL BACK DOOR LINK SUB-ASSY LOWER Install the link sub-assy with the bolts. Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
23. INSTALL BACK DOOR SIDE FEMALE STOPPER SUB-ASSY RH Install the female stopper with the 2 bolts. Torque: 7.0 N.m (71 kgf.m, 62 in.lbf)
24. INSTALL W/MOTOR BACK DOOR LOCK ASSY Apply MP grease to the sliding and rotating parts of the door lock assy. If reusing door lock assy: Install a new door lock wire harness packing. NOTE: If reusing the door lock that has been removed, replace the packing in the connecting part with a new one. Be careful that no grease and dirt sticks to the packing surface in the connecting part. Reusing removed packing or using damaged packing will allow water to penetrate through to the connecting part, resulting in a malfunction of the door lock. Insert the outside handle link into the door lock, and then set it to the door panel. NOTE: Make sure that the outside handle link is securely engaged with the lock assembly. Apply adhesive to the threads of the screws. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Using a torx(R) socket wrench (T30), install the door lock assy with the 3 screws. Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf) Connect the door lock connector.
25. INSTALL BACK DOOR OUTSIDE HANDLE Install the handle with the 2 bolts. Torque: 5.0 N.m (51 kgf.cm, 42 in.lbf)
26. INSTALL STEREO COMPONENT SPEAKER ASSY (W/ SPEAKER) (SEE «STEREO COMPONENT SPEAKER ASSY»(ref-228804-S18232601072006041100000) )
27. INSTALL BACK DOOR SERVICE HOLE COVER (W/ SPEAKER) Apply butyl tape to the door (Scheme 252) Adhesive: Part No. 08850-00065, Butyl Tape Set or equivalent Install the service hole cover. HINT: When installing the service hole cover, pull out the links and connectors through the service hole cover. There should be no wrinkles or folds after attaching the service hole cover. After attaching the service hole cover, confirm the sealing condition. Dimensions: Install the 2 tool box brackets with the 4 bolts. Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)