Hyundai Sonata: Rear Door. Repair procedures - Exterior - Body (Interior and Exterior)Hyundai Sonata: Rear Door. Repair procedures

Replacement

Door Trim Replacement
•
Be careful not to scratch the door trim and other parts.
•
Put on gloves to protect your hands.
1.
Remove the delta inner cover (A).
2.
Remove the inside handle cover (A).
3.
After loosening the mounting screws, then remove the rear door trim (A).
4.
Disconnect the inside handle cage (A).
5.
Disconnect the connectors (A).
6.
Installation is the reverse of removal.
•
Make sure connectors are connected properly and each rod is connected securely.
•
Make sure the door locks/unlocks and opens/closes properly.
Inside Handle Replacement
1.
Remove the rear door trim.
2.
After loosening the mounting screws, then remove the inside handle (A).

3.
Installation is the reverse of removal.
•
Make sure the door locks/unlocks and opens/closes properly.
Glass Replacement
•
Put on gloves to protect your hands.
1.
Remove the rear door trim.
2.
Remove the rear door belt inside weatherstrip (A).
3.
After loosening the mounting screws, then remove the delta outer cover (A).
4.
Release the rear channel mounting bolts and nut.
5.
Remove the glass mounting hole plug (A).
•
Using the door switch to aligh the mounting hole with the hole on the door glass.
•
If it is impossible, aligh the hole by hand after removing the motor.
•
Be careful not to drop to glass and scratch the glass surface.
6.
Carefully move the glass (B) 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:
3.9 ~ 2.9 N.m (0.4 ~ 1.2 kgf.m, 11.8 ~ 8.7 lb-ft)

7.
Installation is the reverse of removal.
•
Roll the glass up and down to see if it move freely without binding.
•
Adjust the glass position as needed.
Speaker Replacement
1.
Remove the rear door trim.
2.
After loosening the mounting screws, then remove the speaker (B).
3.
DIsconnect the speaker connector (A).
4.
Installation is the reverse of removal.
•
Make sure connectors are plugged in properly.
Power Window Motor Replacement
1.
Remove the rear door trim.
2.
Disconnect the power window motor connector (A).
3.
After loosening the mounting screws, then remove the power window motor (B).
4.
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.
After loosening the mounting bolt, then remove the outside handle cover (A).
Tightening torque:
0.7 ~ 0.5 N.m (0.07 ~ 0.1 kgf.m, 1.0 ~ 0.7 lb-ft)

2.
Remove the outside handle (A) by sliding it rearward.
3.
Installation is the reverse of removal.
Module Assembly Replacement
1.
Remove the following parts:
A.
Door trim
B.
Window glass
C.
Outside handle
D.
Rear channel
2.
Loosen the mounting screw (A).
3.
After loosening the door module mounting bolts, remove the door module (A).
Tightening torque:
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

4.
Disconnect the connector (A).
5.
Detach the clips, then remove the wiring harness (B).

6.
Installation is the reverse of removal.
•
The area of whole parts should be applied with sufficient grease.
•
Make sure connectors are connected properly and each rod is connected securely.
•
Make sure the door locks/unlocks and opens/closes properly.
Door weatherstrip Replacement
1.
Loosen the door check arm mouting bolts.
2.
Detach the clips, then remove the weatherstrip (A).
3.
Installation is the reverse of removal.

Adjustment

Glass Adjustment
•
Check the glass run channel for damage or deterioration, and replace them necessary.
1.
Remove the following parts.
A.
Door trim.
2.
Carefully move the glass (A) until the glass mounting bolts are visible, then loosen them.
3.
Check that the glass moves smoothly.
4.
Raise the glass fully, and check for gaps. Check that the glass contacts the glass run channel evenly.
Door Position Adjustment
•
After installing the door, check for a flush fit with the adjacent body panels, 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.
Place the vehicle on a firm, level surface when adjusting the doors.
2.
Check that the door and body edges are parallel.
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): 34.3 ~ 41.2 N.m (3.5 ~ 4.2 kgf.m, 25.3 ~ 30.4 lb-ft)
(C): 21.6 ~ 26.5 N.m (2.2 ~ 2.7 kgf.m, 15.9 ~ 19.5 lb-ft)

4.
Grease the pivot portions of the hinges indicated by the arrows.
5.
Check for water leaks.
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 fine 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.

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