16/11/2023 09:25:47

Handle - Exterior Release - Door - Rear - LH - Generation 2.1 (Retrofit)

Correction Code 11452016

  • 2023-11-16: Added correct image of the LED harness cavity.
  • 2023-10-25: Rearranged installation steps.
  • 2023-08-30: Revised title for the hyperlink for the recalibration procedure.

Special tool(s) required for this procedure:

Part Number Description
1103741-20-A Window switch tool (rear)
1080985-10-A Door handle alignment kit
1054712-00-A Thread setter kit (NA, APAC)
1054712-01-A Blind nut kit (EMEA)
1004296-00-A Service rivnut
1015888-00-C Service bolt
1118491-00-A SEALED CONNECTOR PLUG, LED (base door handles)

Generation 2.0 Handle Assembly Removal

  1. Open the door and use a pen or similar object to close the door latch.
    Informational PurposesAn informational icon, calling your attention
    Note
    The latch mechanism is closed after 2 clicks.
  2. Shift into Neutral and touch the Park Brake icon on the touchscreen.
  3. Fully raise the door glass.
  4. Make sure the door handle is retracted.
  5. Use masking tape on the outside of the vehicle to mark the position of the window glass relative to the door panel.
  6. Use masking tape to cover the exterior side of the door handle grip.
  7. Remove the door glass (refer to procedure).
  8. Place the glass in a safe location during the remainder of this procedure.
  9. Discard the door closeout panel.
  10. Connect the window switch tool to the door handle harness.
  11. Use the window switch tool to fully lower the door glass holding clips.
  12. Using a pry tool, remove the clip that secures the door handle harness inside the door cavity.
  13. Disconnect the door handle harness from the door handle assembly.
  14. Release the door handle harness edge clips (x2) located on the rear side of the inner door cavity.
  15. Remove the nuts that attach the door handle assembly to the door outer panel (torque 9 Nm).
  16. Carefully remove the assembly from the vehicle.
  17. Position the assembly on a soft working surface.
  18. Remove and discard the door handle assembly rear seal.
  19. Remove the screws (x4) that attach the backplate to the handle grip (torque 2 Nm), and then remove the backplate from the assembly.
  20. Remove the hand grip from the assembly.
  21. Discard the old door handle assembly.

Generation 2.1 Handle Assembly Installation

  1. Position the new door handle assembly on a soft working surface.
  2. Remove and discard the door handle assembly rear seal.
  3. Remove the screws (x4) that attach the backplate to the handle grip (torque 2 Nm), and then remove and discard the backplate.
  4. Id equipped, remove the LED from the rear of the hand grip, but do not remove it from the door handle assembly.
    Informational PurposesAn informational icon, calling your attention
    Note
    Base door handles do not have LEDs.
  5. Remove and discard the hand grip.
  6. Install spacers on the handle fork.
    1. Remove the tape covering the adhesive on the spacer for the front-most fork arm.
    2. Place the spacer, with the adhesive side down, on the front-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    3. Remove the tape covering the adhesive on the spacer for the rear-most fork arm.
    4. Place the spacer, with the adhesive side down, on the rear-most fork arm so that the angled edge is oriented correctly to the fork arm, and the hole in the center of the spacer aligns with the hole on the grip-side of the fork handle.
    5. Remove the tape covering the adhesive on the second spacer for the rear-most fork arm.
    6. Place the spacer, with the adhesive side down, in the center of the small vertical area above the hole on the rearmost fork arm.
  7. Install the hand grip from the old door handle assembly.
  8. Install the handle grip LED assembly (or dummy plug) in the rear of the handle grip.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    If the handle was not equipped with an LED because it was a base version, install a dummy plug (1118491-00-A) in the empty cavity to prevent water ingress. If a dummy plug is not available, tape can be used to seal the connector cavity instead.
    Figure 1. Empty cavity for LED
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the LED harness is properly routed.
  9. Install the painted backplate from the old door handle assembly, and tighten the screws (x4) that attach the backplate to the handle grip (torque 2 Nm).
    Warning IconA warning icon, calling your attention to a possibly risky situation
    CAUTION
    Make sure that the LED harness is properly routed before tightening the screws.
  10. Install a new door handle rear seal on the exterior door release handle assembly:
    1. Align the holes in the new door handle rear seal to the studs on the exterior door release handle assembly.
    2. Use a cable tie to secure the seal to the assembly.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      To avoid damage to the electrical harness, properly route the wires.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      To avoid damage to the seal, do not over-tighten the cable tie.
    3. Use a suitable tool, such as a socket extension, to press the outside edge of the seal firmly against the assembly.
    4. Use a deep 5 mm socket to press the push nuts onto the studs.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Do not use excessive force to press the push nuts onto the studs.
    5. Verify that each push nut is set onto its stud with no gap between the seal and assembly.
  11. Connect the door handle harness to the door handle assembly.
  12. Install the door handle assembly in the door body, and hand tighten the nuts (x4).
  13. Use the door handle alignment tool to align the door handle.
  14. Make sure the front and rear of the door handle are flush with the outside of the door panel and the handle fit is consistent with the other door handles on the vehicle.
    1. If the door handle alignment is correct, skip to step 15.
    2. If the door handle appearance is not consistent with the other handles installed on the vehicle, remove the nuts installed in step 12.
    3. To achieve a fit consistent with the other door handles on the vehicle, install or remove shims around the door handle mounting studs on the inboard side of the door panel.
      Informational PurposesAn informational icon, calling your attention
      Note
      To achieve the correct fit, 1 shim (1.5mm thick) on each door handle mounting stud is nominal. If necessary to achieve the correct fit, try combinations of 1 or 2 shims, up to a total of 3.0mm total thickness for all shims on any of the 4 door handle mounting studs.
      Warning IconA warning icon, calling your attention to a possibly risky situation
      CAUTION
      Failure to properly align the door handle with the outside of the door panel can result in improper fitment, and therefore repeat repair of the door handle.
    4. Install the door handle assembly in the door body, and hand tighten the nuts (x4).
    5. Use the door handle alignment tool to align the door handle.
    6. Repeat step 14 as necessary to achieve the correct fit.
  15. Tighten the nuts (x4) that attach the door handle assembly to the door outer panel (torque 9 Nm).
  16. Carefully install the outer flap seal and the door glass seal, starting from the rear part of the door, and moving towards the front (refer to procedure (refer to procedure)).
  17. Install the door glass and raise the window.
  18. Insert the edge of the door glass in the rear regulator clip and secure the glass in the clip.
  19. Adjust the door glass to the previously marked position and tighten the nut that secures the door glass to the front regulator (torque 7.5 Nm).
  20. Remove the tape from the window glass.
  21. Install waterproof tape over the holes (x5) in the inner door.
  22. Align the new closeout panel in the regulator access opening inside the door frame and use masking tape to temporarily attach the panel in place.
    Tip: Make sure the new closeout panel is evenly aligned around the opening.
  23. Use a paint pen to mark the locations (x5) for the mounting holes.
    Tip: Do not to move the closeout panel when applying marks for mounting points.
  24. Drill a 7.75 mm hole at each of the marked locations (x5).
    Tip: For best results, and to catch some of the metal shavings, apply a coating of white lithium grease to the drill bit and drill at low speed.
  25. Wipe off the freshly drilled surfaces (inside and outside the door frame) and remove any metal shavings from inside the door cavity.
  26. Use the rivnut setting tool with an M5 bit to install a rivnut in each hole drilled.
  27. Drill a 25 mm. hole in the closeout panel where indicated.
    Informational PurposesAn informational icon, calling your attention
    Note
    The location for the hole is indicated on the inboard side of the closeout panel.
  28. Connect the door handle wiring harness to the door harness and attach the door handle wiring harness to the inner door frame with a push clip.
  29. Install the door handle wiring harness clip to the door frame.
  30. Install the harness edge clips on the door frame. Make sure to leave enough clearance for the window regulator.
  31. Route the door handle harness from inside the door panel cavity through the hole in the closeout panel and seat the sealing grommet.
  32. Install the updated closeout panel and make sure the manual door handle release cable is routed properly.
  33. Tighten the screws (x5) to attach the closeout panel to the door frame (torque 4 Nm).
  34. Insert the tabs on the bottom of the door handle module into the retainers on the closeout panel.
  35. Install and tighten the screw (x1) to hold the top of the door handle module to the closeout panel (torque 2 Nm).
  36. Connect the window switch tool to the door harness connector.
  37. Raise and lower the window several times and make sure the door handle wiring harness and connectors are not in the path of the window glass as it moves up and down.
  38. Disconnect the window switch tool from the door harness connector.
  39. Connect the door handle wiring harness to the door handle module mounted on the closeout panel.
    Warning IconA warning icon, calling your attention to a possibly risky situation
    Warning
    Always replace plugs or tape removed from the front door shells when servicing or inspecting the door or its components. Additional holes in the door creates more escape paths for air, which decreases the front door pressure sensor's ability detect a side impact, and can negatively affect airbag deployment.
  40. Install the LH rear door trim panel (refer to procedure).
    Informational PurposesAn informational icon, calling your attention
    Note
    Do not close the door after the trim panel is installed.
  41. Perform the door exterior release handle recalibration procedure. See Handle - Exterior Release - Door (Recalibrate).
  42. Perform a firmware reinstall. See Firmware Reinstall - Touchscreen.
  43. Verify the operation of all door handles.