Removal and Replacement
Rear Doors
Rear Door And Door Component Carrier, Removing And Installing
1 - Door component carrier
NOTE: Before removing, mark the position of the door component carrier on the door using a fine felt-tip pen or equivalent.
Removing:
- Remove door trim panel.
- Disengage Bowden cable for door lock.
- Disengage rubber boot from B-pillar and disconnect harness connector.
- Remove bolts - 3 -, - 4 -, - 6 - and - 7 -.
- Lift door component carrier up and out of door shell.
Installing:
NOTE: The rear door - 5 - must be adjusted before adjusting the door component carrier.
- First install door component carrier in door shell and secure loosely with bolts - 3 -, - 4 -, - 6 - and - 7 - and adjusting plate - 2 -.
- Shut door, check adjustment and readjust door component carrier as necessary.
- Repeat check and adjustment if necessary.
- Tighten bolts to 30 Nm (22 ft lb) in sequence: - 3 -, - 7 -, - 6 - and - 4 -.
CAUTION: Tighten bolts in the specified sequence: - 3 -, - 7 -, - 6 - and - 4 -.
2 - 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 - 2 -.
3 - Bolt w/washer assembly
- 30 Nm (22 ft lb)
4 - Bolt w/washer assembly
- 30 Nm (22 ft lb)
5 - Rear door
NOTE: The door component carrier does not have to be disassembled to remove the rear door.
- Remove bottom section of B-pillar trim.
- Disconnect harness connectors at connection point on B-pillar.
- Unclip rubber boot between front door and B-pillar and pull wiring harness and central locking wiring harness out from B-pillar.
- Remove Torx(R) bolts securing top and bottom hinges to door, and remove door complete with door component carrier.
- Panel gap dimensions.
6 - Bolt w/washer assembly
- 30 Nm (22 ft lb)
7 - Bolt w/washer assembly
- 30 Nm (22 ft lb)
Upper door hinge
- To remove door shell, remove bolt - 3 -.
Tightening torque: 30 Nm (22 ft lb)
NOTES:
- Door hinge - 2 - can also be separated at stud - 4 - (tightening torque: 23 Nm, or17ft lb).
- Item - 5 - is a cover cap.
- To remove door hinge - 2 -, also remove bolts - 1 - (2x).
Tightening torque: 30 Nm (22 ft lb)
Lower door hinge
- To remove door shell, remove bolts - 3 -.
Tightening torque: 30 Nm (22 ft lb)
- To remove door hinge - 2 -, also remove bolts - 1 - (2x).
Tightening torque: 30 Nm (22 ft lb)
- Grease areas indicated by arrows with G 000 150.
Disengaging Bowden cable
- Unclip Bowden cable - 5 - from clip - 4 -.
- Remove bolt - 3 - from relay lever.
- Unclip relay lever and disengage Bowden cable - 5 -.
Bowden cable - 1 - is for the interior door handle.
Panel gaps for rear door
Dimension -B- = 4.5 mm ± 0.5 mm (0.177 in. ± 0.019 in.)
Dimension -C- = 3.5 mm ± 0.5 mm (0.138 in. ± 0.019 in.)