Overhaul

Rear Door And Door Component Carrier, Removing And Installing







1 - Bolts (2x)
- 30 Nm (22 ft.lb)
2 - Rear door

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

Removing:
- Remove door component carrier - 3 -.
- Remove screws for upper door hinge Fig. 1.
- Remove screws for lower door hinge Fig. 2.

Installing:
- Install in reverse order of removal.

Adjusting:
- Adjusting







3 - Door component carrier

Removing:
- Remove door trim.
- Disengage Bowden cable for door lock Fig. 5.
- Remove boot on B-pillar and disconnect electrical and pneumatic connectors.
- Unscrew bolts - 1 - and - 5 -.
- Lift up door component carrier and remove.

Installing:

NOTE: Rear door - 2 - must be properly adjusted.

- Install in reverse order of removal.
- First place door component carrier in door and slightly tighten bolts - 1 - and - 5 -, then attach using adjusting plate - 4 -.

- Bolts - 1 - and - 5 - must be tightened in specific order a; b; c, then d.

Adjusting:
- Adjusting







4 - Adjusting plate

NOTE: The adjusting plate must always be installed.

- Inclination of door at C-pillar can be adjusted by altering position of adjusting plate - 4 -.
5 - Bolts (2x)
- 30 Nm (22 ft.lb)







Fig. 1 Upper door hinge
- To remove door, remove bolt - 3 -.
Tightening torque: 30 Nm (22 ft.lb)

NOTE: Door hinge - 2 - can also be separated via stud - 4 - (tightening torque 23 Nm/17 ft.lb).

5 - Cap
- To remove door hinge - 1 - remove remaining screws - 1 - (2x).
Tightening torque: 30 Nm (22 ft.lb)







Fig. 2 Lower door hinge
- To remove door, remove bolt - 3 -.
Tightening torque: 30 Nm (22 ft.lb)
- To remove door hinge - 2 - remove remaining screws - 1 - (2x).
Tightening torque: 30 Nm (22 ft.lb)
- Grease at point -1a- using grease type G 000 150.







Fig. 3 Removing and installing side impact bar
- Remove bolt - 4 - (2x) and remove side impact bar - 5 -.
Tightening torque: 8 Nm (71 in.lb)







Fig. 4 Removing and installing rear door impact absorber
- Remove bolts - 3 - (2x).
Tightening torque: 3 Nm (27 in.lb)
- Remove impact absorber - 2 -.
1 - Insulation liner (2x)







Fig. 5 Bowden cable for door lock
- Detach Bowden cable - 4 - from clips - 5 - and - 3 -.
- Remove plastic screw from hinge arm - 2 -.
- Unclip hinge arm - 2 - and detach Bowden cable.
1 - Bowden cable for interior door mechanism