Front Door and Door Component Carrier, Removing and Installing

Front Door And Door Component Carrier, Removing And Installing







1 - Hex bolts (2x)
- 30 Nm (22 ft.lb)
2 - Front door

NOTE: The door component carrier does not have to be disassembled in order to remove the front door.

Removing:
- Remove front door trim.
- Remove bottom section of A-pillar trim.
- Disconnect vacuum line connectors at connection point on A-pillar.
- Unclip rubber boot between front door and A-pillar, and pull wiring harness and central locking wiring harness out from A-pillar.
- Remove door component carrier - 3 -.







- Unscrew bolts - 1 - and - 5 -.
- Remove screws for upper door hinge Fig. 2.
- Remove screws for lower door hinge Fig. 3.

Installing:
- Install in reverse order of removal.

Adjusting:
- To adjust.

3 - Door component carrier

Removing:
- Remove door trim.
- Disconnect harness connectors and unclip from door component carrier.
- Remove bolts - 1 - and - 5 - and lift door component carrier upward and out.

Installing:
- Install in reverse order of removal.

CAUTION: Bolts - 1 - and - 5 - must be tightened in the order - a -, - b -, - c -, then - d -.







Adjusting:
- Adjust via adjusting plate - 4 -.
- Dimensional requirements.

NOTE:
- The rear door component carrier must be adjusted first, if it has not been already.
- Adjustment order: Rear door component carrier, trim post - B - and then front door component carrier.







4 - Adjusting plate

NOTE: The adjusting plate must always be installed.

- Inclination of door at B-pillar can be adjusted by altering position of adjusting plate - 4 -.

5 - Bolts (2x)
- 30 Nm (22 ft.lb)
6 - Bowden cable

CAUTION: Route cable - 6 - exactly as shown in diagram (between carrier - 7 - and window guide - 8 -) in order to avoid malfunctions.

7 - Carrier
8 - Window guide







Fig. 1 Bowden cable routing
1 - Bowden cable
2 - Window guide
3 - Carrier

CAUTION: Route cable - 1 - exactly as shown in diagram (between carrier - 3 - and window guide - 2 - ) in order to avoid malfunction.







Fig. 2 Upper door hinge
- To remove door, remove bolt - 4 -.
Tightening torque: 30 Nm (22 ft.lb)

NOTE: Door hinge - 2 - can also be separated via bolt - 5 - (tightening torque: 23 Nm/17ft.lb).

- To remove door hinge - 2 - also remove bolts - 1 - and - 3 -.
Tightening torque: 30 Nm (22 ft.lb)







Fig. 3 Lower door hinge
- To remove door, remove bolts - 4 - and - 6 -.
Tightening torque: 30 Nm (22 ft.lb)

- To remove the door hinge - 2 - also remove bolts - 1 - and - 3 -.
Tightening torque: 30 Nm (22 ft.lb)
- Grease at point -2a- using grease type G 000 150.

Removing And Installing Side Impact Bar







- To remove, remove bolt - 5 - (2x) and remove side impact bar - 6 -.
Tightening torque: 8 Nm (71 in.lb)