RM35X0E _59 Vehicle Exterior _078503 DOOR / HATCH _0397542 SLIDE DOOR(for Wagon) A

DOOR / HATCH  SLIDE DOOR(for Wagon)  REASSEMBLY  


CAUTION / NOTICE / HINT

HINT:
·

Use the same procedure for RHD and LHD vehicles.

·

The procedure listed below is for LHD vehicles.

·

Use the same procedure for the RH and LH sides.

·

Use the same procedure described for the RH side.

·

A bolt without a torque specification is shown in the standard bolt chart.

Click hereGeneral>SPECIFICATIONS>STANDARD BOLT>SPECIFIED TORQUE FOR STANDARD BOLTS



PROCEDURE

Hide 1.INSTALL CUSHION

a.
B539171

Attach the claw and install the cushion.


Hide 69485D 2.INSTALL SLIDE DOOR OPEN STRIKER RH

a.
B539170

Install the slide door open striker RH with the 3 bolts.

Torque:
27.5 N*m (280 kgf*cm, 20 ft.*lbf)


Hide 69416B 3.INSTALL SLIDE DOOR DOWN MALE STOPPER

a.
B539169

Temporarily install the slide door down male stopper with the 2 bolts.

HINT:

When installing the slide door down female stopper, install the slide door down male stopper.



Hide 67155C 4.INSTALL REAR DOOR CORNER BRACKET RH (w/ Rear Seat)

a.
B539168
1.594,0.365 1.823,0.573 0.229,0.208 10 true (1) 0.948,1.385 1.177,1.594 0.229,0.208 10 true (2)

Install the rear door corner bracket RH with the 2 bolts.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


Hide 69418L 5.INSTALL SLIDE DOOR OPEN STOP RH

a.
B539167

Temporarily install the slide door open stop RH with the 2 bolts.

HINT:

When installing the slide door upper roller assembly RH, install the slide door open stop RH.



Hide 68335C 6.INSTALL SLIDE DOOR LOWER ROLLER ARM RH

a.
B539166

Install the slide door lower roller assembly RH with the 4 bolts.

Torque:
19.5 N*m (199 kgf*cm, 14 ft.*lbf)


Hide 68301C 7.INSTALL SLIDE DOOR UPPER ROLLER ASSEMBLY RH

a.
B539165

Temporarily install the slide door upper roller assembly RH with the 2 bolts.


b.

Fully close the rear door panel sub-assembly RH.


c.

Tighten the 2 bolts and install the slide door open stop RH.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


d.

Tighten the 2 bolts and install the slide door upper roller assembly RH.

Torque:
11.5 N*m (117 kgf*cm, 8 ft.*lbf)


Hide 68380D 8.INSTALL SLIDE DOOR CENTER HINGE ASSEMBLY RH

a.
B539172
0,0 0,0 false
V100155

MP grease


Apply MP grease between the pin and roller as shown in the illustration.


b.
B539164

Install the slide door center hinge assembly RH with the 2 bolts.

Torque:
19.5 N*m (199 kgf*cm, 14 ft.*lbf)


Hide 67003 9.INSTALL REAR DOOR PANEL SUB-ASSEMBLY RH

a.
B494735
0,0 0,0 false
V100155

MP Grease


Apply MP grease to the lower slide door rail RH as shown in the illustration.


b.
B538385
2.365,3.729 2.083,3.375 true 2.365,3.729 2.604,3.927 0.24,0.198 10 true *a
*a Cutout


Rotate the roller part of the slide door lower roller arm sub-assembly RH counterclockwise to connect the slide door lower roller arm sub-assembly RH to the cutout of the slide door motor unit RH.

NOTICE:
·

Support the lower portion of the slide door RH when connecting the slide door lower roller arm sub-assembly RH, as the slide door RH becomes unstable.

·

Work with 2 or more persons when connecting the slide door RH in order to prevent deformation and damage.




c.
B539173
0,0 0,0 false
V113147

Install in this Direction


Install the slide door center hinge assembly RH from the rear part of the center slide door rail RH.


d.
B539174
0,0 0,0 false
V113147

Install in this Direction


Install the roller part of the slide door upper roller assembly RH from the rear part of the upper slide door rail RH, and then install the slide door RH as shown in the illustration.


e.

w/ Power Slide Door:

i.
B538378

Move the slide door RH so that the 2 bolts are visible as shown in the illustration.


ii.

Connect the slide door lower roller assembly RH to the slide door motor unit RH with the 2 bolts.

Torque:
7.8 N*m (80 kgf*cm, 69 in.*lbf)



f.
B538386
0,0 0,0 false
V113147

Install in this Direction


Install the wire harness protector.

i.

Attach the clip as shown in the illustration.


ii.

Install the wire harness protector with the bolt.

Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)



g.
B538375
0,0 0,0 false
V100135

Ground Bolt
V100136

Connector


Connect the wire harness (w/o Power Slide Door).

i.

Connect the 2 connectors.


ii.

Install the ground wire with the ground bolt.

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)



h.
B538376

Connect the wire harness (w/ Power Slide Door).

i.

Connect the 4 connectors.



Hide 68325 10.INSTALL SLIDE DOOR UPPER RAIL CUSHION RH

a.
B555246
0,0 0,0 false
V113147

Install in this Direction


Attach the guide and install the slide door upper rail cushion RH as shown in the illustration.


Hide 67887D 11.INSTALL NO. 2 SLIDE DOOR WEATHERSTRIP RH

a.

Remove any non-drying sealer on the body with non-residue solvent.


b.
B539176
2.188,1.615 2.385,1.479 true 2.427,1.365 2.615,1.542 0.188,0.177 10 true *a
*a Matchmark
V113147

Install in this Direction


Align the matchmark on the body side with the matchmark on a new No. 2 slide door weatherstrip RH and install the No. 2 slide door weatherstrip RH as shown in the illustration.

NOTICE:

When installing, make sure that non-drying sealer does not adhere to the body and slide door.


HINT:
B539177
1.729,1.063 2.865,0.865 true 2.906,0.75 3.313,1.094 0.406,0.344 10 false *a
*a Vehicle Body


Check that the No. 2 slide door weatherstrip RH contacts the body surface.



Hide 68073 12.INSTALL SLIDE RAIL END MOULDING SUB-ASSEMBLY RH

a.
B539178
0.583,3.208 0.948,3.542 false 0.396,3.115 0.708,3.313 0.313,0.198 10 false *a
*a Clip (part a)
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Slide the slide rail end moulding sub-assembly RH in the direction (1) indicated by the arrow shown in the illustration and attach the guide.


b.

Push the clip (part a) in the direction (2) indicated by the arrow shown in the illustration and install the slide rail end moulding sub-assembly RH.


Hide 67897M 17.INSTALL NO. 4 SLIDE DOOR WEATHERSTRIP RH

a.
B551452
1.917,0.198 2.375,0.396 0.458,0.198 10 false (1) 1.906,0.51 2.365,0.708 0.458,0.198 10 false (2) 1.906,0.917 2.365,1.115 0.458,0.198 10 false (3) 1.917,1.323 2.375,1.521 0.458,0.198 10 false (4) 1.896,1.573 2.354,1.771 0.458,0.198 10 false (5) 1.885,1.865 2.344,2.063 0.458,0.198 10 false (6)

Attach the clip and install the No. 4 slide door weatherstrip RH in the order shown in the illustration.


Hide 67837C 18.INSTALL REAR DOOR DUST PROOF SEAL

a.
B539158

Attach the claw and install the rear door dust proof seal.

HINT:

Use the same procedure described for the other side.



Hide 19.INSTALL CUSHION

a.
B539157

Attach the claw and install the cushion.

HINT:

Use the same procedure described for the other side.



Hide 69425C 20.INSTALL SLIDE DOOR STOP CUSHION (w/o Power Slide Door)

a.
B539156

Attach the guide.


b.

Using a T30 "TORX" socket wrench, install the slide door stop cushion with the "TORX" screw.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


Hide 67785D 21.INSTALL REAR DOOR UPPER TRIM COVER RH (w/ Rear Seat)

a.
B539180
0,0 0,0 false
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Attach the claw and install the rear door upper trim cover RH as shown in the illustration.


Hide 67161B 22.INSTALL SLIDE DOOR UPPER INSIDE PANEL EXTENSION RH (w/ Rear Seat)

a.
B539181
1.135,0.448 1.344,0.646 0.208,0.198 10 true (1) 1.292,1.635 1.5,1.833 0.208,0.198 10 true (2)

Install slide door upper inside panel extension RH with the 2 bolts in the order shown in the illustration.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

HINT:

Install the slide door upper inside panel extension RH so that the arrow mark faces the top of the vehicle as shown in the illustration.



Hide 69415 23.CONNECT SLIDE DOOR DOWN FEMALE STOPPER

a.
B551449

Connect the slide door down female stopper with the bolt.


Hide 67865D 25.INSTALL CENTER PILLAR UPPER END WEATHERSTRIP RH (w/o Power Slide Door)

a.
B539682

Attach the claw and install the 5 screw grommets.


b.

When using a new center pillar upper end wetherstrip RH:

i.

Remove the release paper from the center pillar upper end wetherstrip RH.

HINT:

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




c.
B551453
0,0 0,0 false
V113147

Install in this Direction


Temporarily install the center pillar upper end weatherstrip RH with the temporary screw.


d.
B552474
0,0 0,0 false
V100135

Screw
V100136

Bolt


Install the center pillar upper end weatherstrip RH with the bolt and 5 screws.

Torque:
Bolt : 7.5 N*m (76 kgf*cm, 66 in.*lbf)


Hide 69415 26.INSTALL SLIDE DOOR DOWN FEMALE STOPPER

a.
B553203

Temporarily install the slide door down female stopper with the 2 bolts.


b.

Fully close the slide door panel sub-assembly RH.


c.

Tighten the 2 bolts and install the slide door down female stopper.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


d.

Tighten the 2 bolts and install the slide door down male stopper.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


Hide 69630C 29.INSTALL SLIDE DOOR LOCK REMOTE CONTROL ASSEMBLY RH

a.

Apply MP grease to the sliding parts of the slide door lock remote control assembly RH.


b.
B539143C01
0,0 0,0 false
V100135

Bolt
V100136

Connector


Attach the guide and install the slide door lock remote control assembly RH with the 4 bolts.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


c.

Connect the each connector.


Hide 69200 31.INSTALL POWER SLIDE DOOR LOCK ASSEMBLY RH (w/ Power Slide Door)

Hide 69230 34.INSTALL REAR DOOR OUTSIDE HANDLE ASSEMBLY RH

a.

Apply MP grease to the sliding part of the rear door outside handle assembly RH.


b.
B539129

Install the rear door outside handle assembly RH with the 2 bolts.

Torque:
5.5 N*m (56 kgf*cm, 49 in.*lbf)


c.
B539128

Install the hole plug.


Hide 69713A 35.INSTALL REAR DOOR LOCK REMOTE CONTROL LINK RH

a.
B539193
0,0 0,0 false
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Connect the rear door lock remote control link RH in the direction indicated by the arrow (1) as shown in the illustration.


b.

Attach the snap in the direction indicated by the arrow (2) as shown in the illustration.


c.
B540693

Attach the clamp and install the rear door lock remove control link RH.


d.

When using a new rear door outside handle assembly RH:

i.

Remove the protective tape from the rear door outside handle assembly RH.



Hide 69070 36.INSTALL SLIDE DOOR HANDLE ASSEMBLY RH

a.

Apply MP grease to the sliding part of the slide door handle assembly RH.


b.

Detach the clamp.


c.

Straighten each cable, position them as shown in the illustration and install them with each clamp.

B539194
3.781,2.052 4.208,2.052 false 4.354,2.583 4.698,2.583 false 4.896,1.75 5.24,1.75 false 5.135,2.479 5.448,2.677 0.313,0.198 10 false *a 3.594,1.958 3.906,2.156 0.313,0.198 10 false *a 1.073,0.292 1.385,0.49 0.313,0.198 10 false *c 5.292,1.656 5.604,1.854 0.313,0.198 10 false *c 0.354,2.396 0.667,2.594 0.313,0.198 10 false *b 4.177,2.49 4.49,2.688 0.313,0.198 10 false *b 6.375,3.823 6.688,4.021 0.313,0.198 10 false A 2.302,1.531 2.615,1.729 0.313,0.198 10 false C 1.635,3.781 1.948,3.979 0.313,0.198 10 false B
*a Locking Cable (Orange) *b Close Cable (Purple)
*c Open Cable (Blue) - -


Standard:
Area Standard Dimension Area Standard Dimension
A 59.6 to 61.2 mm (2.35 to 2.41 in.) B 57.7 to 59.3 mm (2.27 to 2.34 in.)
C 41.35 to 42.75 mm (1.63 to 1.68 in.) - -



d.

Attach the clamp.


e.
B539195
0,0 0,0 false
V113147

Install in this Direction


Insert each cable into the service hole and install the slide door handle assembly RH with the 2 bolts.

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)


f.
B539125

Attach the clamp.


g.
B539196
1.552,2.51 1.729,2.688 0.177,0.177 10 true *a 1.542,0.281 1.729,0.458 0.188,0.177 10 true *b 2.521,1.198 2.698,1.375 0.177,0.177 10 true *c
*a Locking Cable (Orange)
*b Open Cable (Blue)
*c Close Cable (Purple)
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Attach the 3 snaps and connect the 3 cables to the slide door lock remote control assembly RH as shown in the illustration.


h.

Attach the clamp.


Hide 69050 37.INSTALL SLIDE DOOR FULL OPEN STOP LOCK ASSEMBLY RH

a.

Apply MP grease to the sliding part of the slide door full open stop lock assembly RH.


b.
B539123

Install the slide door full open stop lock assembly RH with the 2 bolts.

Torque:
5.5 N*m (56 kgf*cm, 49 in.*lbf)


c.
B539122

Attach the clamp.


Hide 85975A 38.INSTALL SLIDE DOOR CLOSER RELAY (w/o Power Slide Door)

a.
B552473

Attach the claw and install the clip.


b.
B552472
0,0 0,0 false
V100135

Bolt
V100136

Connector


Connect the connector.


c.

Attach the guide and install the slide door closer relay with the bolt.

NOTICE:

Do not reuse a slide door closer relay that has been subjected to an impact or dropped.



Hide 67851E 39.INSTALL SLIDE DOOR SERVICE HOLE COVER RH

a.
B551454
2.406,0.875 2.573,0.438 true 2.313,0.229 2.583,0.365 true 2.26,0.917 2.458,1.083 0.198,0.167 10 true *a 2.094,0.146 2.292,0.313 0.198,0.167 10 true *a
V100143

Butyl tape


Apply new butyl tape to the slide door panel.

HINT:
·

Begin applying the butyl tape from the reference point shown in the illustration.

·

The butyl tape can be applied from either reference point.




b.
B551455
0,0 0,0 false
V113147

Install in this Direction


Pass the rear door wire RH through a new slide door service hole cover RH.


c.
B551456
0.719,0.542 0.833,0.646 true 2.469,0.594 2.563,0.49 true 0.542,0.406 0.708,0.573 0.167,0.167 10 true *a 2.563,0.365 2.76,0.563 0.198,0.198 10 true *a
*a Reference Point


Align the top of the slide door service hole cover RH with the reference point on the slide door panel and install it.

NOTICE:
·

Securely install the slide door service hole cover RH to prevent wrinkles and air bubbles.

·

There should be no wrinkles or folds after installing the slide door service hole cover RH.

·

After installing the slide door service hole cover RH, check the seal quality.




d.
B551447

Attach the clamp and install the 2 cable clamps.


e.
B551446

Connect the cable to the cable clamp.


f.

Fold back the slide door service hole cover RH, attach the clamp and connect the slide door full open lock sub-assembly cable as shown in the illustration.


g.
B551445

Connect the connector.


h.
B551444

Attach the clamp as shown in the illustration.


Hide 62345B 40.INSTALL NO. 3 SLIDE DOOR WEATHERSTRIP RH

a.
B551443

Attach the clip and install the No. 3 slide door weatherstrip RH.


Hide 67680B 41.INSTALL SLIDE DOOR TRIM BOARD ASSEMBLY RH

a.
B551442

Connect the connector.


b.
B551457
0,0 0,0 false
V113147

Install in this Direction


Attach the claw in the direction indicated by the arrow shown in the illustration.


c.
B551458
0,0 0,0 false
V113147

Install in this Direction


Attach the clip and install the slide door trim board assembly RH in the direction indicated by the arrow shown in the illustration.


d.
B551459

Attach the clip as shown in the illustration.


Hide 67487A 43.INSTALL REAR DOOR REAR GUIDE BRACKET GARNISH RH

a.
B551460
0,0 0,0 false
V113147

Install in this Direction


Attach the claw and clip and install the rear door rear guide bracket garnish RH in the direction indicated by the arrow shown in the illustration.


b.
B551461
0,0 0,0 false
V113146

Place Hand Here
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Place your hand at the position shown in the illustration and attach the guide while pull in the installation direction.


Hide 67667A 44.INSTALL SLIDE DOOR WINDOW GARNISH RH

a.
B551435

w/ Rear No. 2 Speaker assembly:

i.

Connect the connector.



b.
B551462
0,0 0,0 false
V113147

Install in this Direction


Attach the claw and clip and install the slide door window garnish RH in the direction indicated by the arrow shown in the illustration.


c.
B551463
0,0 0,0 false
V113146

Place Hand Here
V113147

Install in this Direction


Place your hand at the position shown in the illustration and attach the guide while pull in the installation direction.


Hide 65988A 45.INSTALL SUNSHADE HOOK (w/ Sunshade)

a.
B563497
0,0 0,0 false
V113147

Install in this Direction


Attach the claw and install the sunshade hook in the direction indicated by the arrow shown in the illustration.

HINT:

Use the same procedure described for the other side.



Hide 67692B 46.INSTALL SLIDE DOOR TRIM UPPER COVER RH

a.
B551465
0,0 0,0 false
V113147

Install in this Direction


Attach the clip and install the slide door trim upper cover RH in the direction indicated by the arrow shown in the illustration.

HINT:

Install the sunshade hook together with the slide door trim upper cover RH.



b.
B551464
0,0 0,0 false
V113147

Install in this Direction (1)
V113148

Install in this Direction (2)


Attach the guide in the direction indicated by the arrow shown in the illustration.


c.
B552477
0,0 0,0 false
V113147

Install in this Direction


w/ Sunshade

i.

Attach the pin in the direction indicated by the arrow shown in the illustration.

HINT:

Use the same procedure described for the other side.




Hide 47.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL (w/ Rear Curtain Shield Airbag)

Hide 48. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL (w/ Rear Curtain Shield Airbag)