Kia Optima Hybrid: Exterior / Rear Door Repair procedures

Kia Optima Hybrid (TF HEV) 2016-2020 Service Manual / Body (Interior and Exterior) / Exterior / 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.	After loosening the mounting screws, then remove the rear door trim (A).

2.	Disconnect the inside handle cage (A).

3.	Disconnect the connector (A).

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.

•	Replace any damaged clips.

Inside Handle Replacement

1.	Remove the rear door trim.

2.	After loosening the mounting screws, then remove the inside handle (A).

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 rear door trim.

Remove the rear door trim seal (A).

•	Replace any damaged door trim seal.

Using a starwrench, loosen the mounting screws.

Tightening torque:

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0lb-ft)

4.	Disconnect the connector (A) and rod (B).

5.	Remove the rear door latch (C).

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.

Glass Replacement

1.	Remove the rear door trim.

2.	Remove the rear door belt inside weatherstrip (A).

3.	After loosening the mounting screw, then remove the rear door belt outer weatherstrip (A).

4.	Using a screwdriver or remover, remove the rear door upper opening weatherstrip (A).

Using a screwdriver or remover, remove the rear door frame moulding (A).

•	Rear door frame moulding needs to be changed to insure product quality.

6.	After loosening the mounting screw and bolt, then remove the rear door div channel (A).

7.	Remove the glass run (B) and then remove the rear door fixed glass (A).

Remove the glass mounting hole plug (B).

•	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.

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:

3.9 ~ 2.9 N.m (0.4 ~ 1.2 kgf.m, 11.8 ~ 8.7 lb-ft)

10.

Installation is the reverse of removal.

•	Roll the glass up and down to see if it moves freely without binding.

•	Adjust the glass position as needed.

Speaker Replacement

1.	Remove the rear door trim.

2.	Disconnect the speaker connector (A).

3.	After loosening the mounting screws, then remove the speaker (B).

Installation is the reverse of removal.

•	Use sheet metal screws to secure the speaker.

•	Make sure connectors are plugged in properly.

•	Make sure the door locks/unlocks and opens/closes properly.

•	Replace any damaged clips.

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).

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 moves freely without binding.

Outside Handle Replacement

1.	Remove the rear door trim.

2.	Remove the hole plug (B).

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)

4.	Remove the outside handle (A) by sliding it rearward.

Installation is the reverse of removal.

•	Make sure the door locks/unlocks and opens/closes properly.

Door Module Replacement

Remove the following parts:

•	Rear door trim

•	Window glass

•	Rear door DIV channel

•	Rear door fixed glass

After loosening the rear door module mounting bolts, then remove the rear door module (A).

Tightening torque:

6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

3.	Disconnect the connectors, then remove the wiring harness (A).

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 Side weatherstrip Replacement

1.	Detach the clips, then remove the rear door side weatherstrip (A).

Installation is the reverse of 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 rear door trim.

2.	Remove the glass mounting hole plug (B).

3.	Carefully move the glass (A) until the glass mounting bolts are visible, then loosen them.

4.	Check that the glass moves smoothly.

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.	Check that the door and body edges are parallel.

2.	Place the vehicle on a firm, level surface when adjusting the doors.

Adjust at the hinges (A):

•	Loosen the door mounting bolts slightly, and move the door in or out until it aligns flush with the body.

•	Loosen the hinge mounting bolts slightly, and move the door backward or forward, up or down as necessary to equalize the gaps.

•

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)

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.

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.

Rear Door Components and Components Location

Components 1. Rear door trim2. Rear door belt inside weatherstrip3. Rear door trim seal4. Rear door module5. Rear door panel6. Rear door side moulding7. Rear door belt outer weatherstrip8. Rear door DIV ...

Body Side Moulding Repair procedures

Replacement Roof Moulding Replacement • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage. • ...

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