| VELOSTER(FS) >2012 > G 1.6 GDI > Body (Interior and Exterior) > Exterior > Rear Door>Repair procedures |

Replacement
Door Trim Replacement
• | Take care not to scratch the door trim and other parts.
• | Put on gloves to protect your hands.
1. | Using a screwdriver or remover, remove the rear door delta inner cover (A).
2. | Using a screwdriver or remover, remove the rear door inside handle cap (B).
3. | After loosening the mounting screws, then remove the rear door trim (A).
4. | Disconnect the inside handle cage (A).
5. | Disconnect the power window connector (A).
6. | Installation is the reverse of removal.
• | Make sure connectors are connected properly and each rod is connected securely.
• | Make sure the door lock and opens properly.
• | Replace any damaged clips.
Inside Handle Replacement
1. | Remove the rear door trim.
2. | After loosening the mounting screws, then remove the rear door inside handle (A).
3. | Installation is the reverse of removal.
• | Replace any damaged clips.
• | Make sure the door lock and opens properly.
Glass Replacement
1. | Remove the following items.
A. | Rear door delta inner cover
B. | Rear door trim
2. | After loosening the mounting screws, then remove the rear door trim seal mounting bracket (B).
3. | Remove the rear door trim seal (A).
• | Replace the door trim seal if it is damaged.
4. | Remove the rear door belt inside weatherstrip (A).
5. | Loosen the rear door outside handle mounting bolts.
Tightening torque : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
6. | Disconnect the rear door outside handle cable (A).
7. | Remove the rear door outside handle (A).
8. | Loosen the rear door channel mounting bolt and nut.
Tightening torque : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft)
9. | Remove the rear door channel (A).
10. | Remove the glass mounting hole plug.
• | Use the door switch to align the mounting hole/bolt with the hole in the door.
• | If unable to operate the window motor, remove the motor and align the hole by hand.
• | Be careful not to drop the glass and/or scratch the glass surface.
11. | Carefully move the glass (A) until you can see the bolts, then loosen them. Separate the glass from the glass run and carefully pull the glass out through the window slot.
Tightening torque : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
12. | Installation is the reverse of removal.
A. | Roll the glass up and down to see if it moves freely without binding.
B. | Adjust the glass position as needed.
C. | Replace any damaged clips.
Speaker Replacement
1. | Remove the rear door trim.
2. | Disconnect the speaker connector (B).
3. | Drill out the rivets to remove the speaker (A).
4. | Installation is the reverse of removal.
• | Use sheet metal screws to secure the speaker.
• | Make sure the connector are connected properly and each rod is connected securely.
• | Make sure the door lock and opens properly.
• | Replace any damaged clips.
Door Power Window Regulator Assembly Replacement
1. | Remove the following items.
A. | Rear door trim
B. | Rear door trim seal
C. | Rear door glass
2. | Loosen the rear door power window regulator mounting nuts.
3. | Disconnect the rear door power window motor connector (A).
Tightening torque : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft)
4. | Remove the rear door power window regulator assembly (A).
5. | Installation is the reverse of removal.
• | Grease should be applied to areas where there is rotational parts and springs.
• | Roll the glass up and down to see if it move freely without binding.
Outside Handle Replacement
1. | Remove the following items.
A. | Rear door delta inner cover
B. | Rear door trim
2. | Loosen the rear door outside handle mounting bolts.
Tightening torque : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7 lb-ft)
3. | Disconnect the rear door outside handle cable (A).
4. | Remove the rear door outside handle (A).
5. | Installation is the reverse of removal.
• | Make sure the door locks/unlocks and opens/closes properly.
• | Replace any damaged clips.
Door Latch Replacement
1. | Remove the following items.
A. | Rear door delta inner cover
B. | Rear door trim
C. | Rear door trim seal
D. | Outside handle
2. | Loosen the rear door channel mounting bolt and nut.
Tightening torque : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3 lb-ft)
3. | Remove the rear door channel (A).
4. | Loosen the rear door latch mounting screws.
Tightening torque : 7.8 ~ 10.8N.m (0.8 ~ 1.1kgf.m, 5.8 ~ 8.0lb-ft)
5. | Remove the rear door latch assembly (A).
6. | Disconnect the rear door latch connector (A).
7. | Installation is the reverse of removal.
• | Make sure the connector is connected properly.
• | Make sure the door locks/unlocks and opens/closes properly.
• | Replace any damaged clips.
Door Side Weaterstrip Replacement
1. | Detach the clips, then remove the rear door side weatherstrip (A).
2. | Installation is the reverse the removal.
• | Replace any damaged clips.
Adjustment
Glass Adjustment
• | Check the glass run channel for damage or deterioration, and replace them if necessary.
1. | Remove the following items.
A. | Rear door delta inner cover
B. | Rear door trim
C. | Rear door trim seal
2. | Carefully move the glass (A) until the glass mounting bolts are visible, then loosen them.
3. | Check that the glass moves smoothly.
Door Striker Adjustment Make sure the door latches securely without slamming it. If necessary adjust the striker (A): The striker nuts are fixed. The striker can be adjusted up or down, and in or out.
1. | Loosen the screws (B) just enough for the striker to move.
Tightening torque: (B) : 16.7 ~ 21.6 N.m (1.7 ~ 2.2 kgf.m, 12.3 ~ 15.9 lb-ft)
2. | Tap on the striker with a plastic hammer to adjust the striker. The striker will not move much, but will give some adjustment.
3. | Hold the outer handle out, and push the door against the body to be sure the striker allows a flush fit. If the door latches properly, tighten the screws and recheck.
Door Position Adjustment
• | After installing the door, check for a flush fit with the Body, then check for equal gaps between the front, rear, and bottom, door edges and the body. Check that the door and body edges are parallel. before adjusting, replace the mounting bolts.
1. | Check that the door and body edges are parallel.
2. | Place the vehicle on a firm, level surface when adjusting the doors.
3. | Adjust at the hinges (A) :
A. | Loosen the door mounting bolts slightly, and move the door in or out until it aligns flush with the body.
B. | Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize the gaps.
C. | Place a shop towel on the jack to prevent damage to the door when adjusting the door.
Tightening torque : (B) : 21.6 ~ 26.5 N.m (2.2 ~ 2.7 kgf.m, 15.9 ~ 19.5 lb-ft) (C) : 34.3 ~ 41.2 N.m (3.5 ~ 4.2 kgf.m, 25.3 ~ 30.4 lb-ft)
4. | Grease the pivot portions of the hinges indicated.
5. | Check for water leaks.