Front Door: Description and Operation
Front Door
=> [ Front Door Handle Assembly Overview ]
=> [ Front Door, Adjusting ]
=> [ Door Adjustment, Checking Using T40038/2 ]
Front Door Handle Assembly Overview
1 - Door Handle Mount
• Slider of mount locks the lugs - arrows - of door handle => [ Secures Door Handle in Mount ].
2 - Front Door
3 - Clip
• Insert operating rod - 5 - in clip, swivel clip 90° and engage at operating rod.
4 - Door Handle
• Removal, refer to=> [ Front Door Handle and Lock Cylinder ] Front Door.
5 - Operating Rod
• Engage in door lock => [ Engaging Operating Rod in Door Lock ].
Secures Door Handle in Mount
• When removing door handle, slider - 2 - is slid away, releasing lugs - 3 - and door handle can be removed from outside.
• Illustration shows door handle in unlocked position.
- When disassembling door handle, insert spindle - 4 - through facing side of door into mount - arrow - using a Screwdriver (T15).
- Rotate spindle counterclockwise to stop until door handle lugs are released.
- Pull off securing clip - 1 - when disassembling lock cylinder. Refer to => [ Front Door Handle and Lock Cylinder ] Front Door.
- Pull door handle out of mount.
Engaging Operating Rod in Door Lock
- When installing a new door lock, clip operating rod - 1 - into casing - 2 -.
- Move slide - 3 - of casing - 2 - upward to engage operating rod.
- Pull securing pin - 4 - out of door lock only after operating rod has been installed.
Front Door, Adjusting
Panel Gap Dimensions
• Rear door must be adjusted.
• You can check panel gap dimensions using 3371 adjustment gauge.
• Dimension - A - = 3.5 mm ± 0.5mm dimension
• - B - = 4.5 mm ± 0.5mm
• Dimension - C - = 3.5mm ±0.5mm
• Dimension - D - = 0 mm +1mm
• The course of the gap must not deviate more than 0.5 mm from parallel.
- Loosen bolts - 1 -.
- Use the markings (arrows - a - and arrows - c -) for side adjustment.
- Slide striker - 2 - until the door is flush with the contour of the chassis.
- Gasket - 3 - must always be replaced.
• Door may only be adjusted for depth (towards car interior) and not for height.
- Use the markings (arrows - b - and arrows - d -) for height adjustment.
- Striker must align in door lock center for correct adjustment.
- Tighten screws to 25 Nm.
Door Adjustment, Checking Using T40038/2
- Use the door adjustment template (T40038/2) as described in the following for testing (for example, for wind noises) and for adjusting door.
- For testing contact pressure of sealing lips on roof trim molding, use a standard bank card - 1 - or similar means.
- For a correct adjustment, adjusting template - 3 - must make contact on roof trim molding -2- and on roof - 1 - - arrow -.
Testing sealing lip/roof trim molding contact
- Using a standard bank card, drive off contact area of sealing lip to roof trim molding with light pressure.
- When doing this, card must not sink in between sealing lip - 1 - and roof trim molding - 2 -.
Door Adjustment at Sides (Inclination Adjustment)
- Template has points of different lengths at arrows - a - and - b -.
- These allow the side adjustment of the doors to be checked.
- On the side with the "max" marking, check whether window frame is seated too far outside.
- On the side with the "min" marking, check whether window frame is seated too far inside.
- Position template at dimension - a - = 200 mm and with cut-out - arrow - facing door window
- Make sure that points - 1 - and - 3 - make contact.
- At point - 2 - of template, there must be a gap.
- In this position (max), doors are adjusted to farthest outward point within tolerance range.
- If there is no gap at point - 2 -, or there is a gap at point - 1 -, the window frame is set too far outward and must be adjusted.
- The side with arrow - b - (min marking) is used to check whether the window frame is located too far inward in relation to the body.
- Position template at dimension - a - = 200 mm and with cut-out - arrow - turned away from door window as depicted in magnified areas of illustration.
- Make sure that points - 2 - and - 3 - make contact on door window.
- At point - 1 - of template, there must be a gap.
- In this position (min), doors are adjusted to farthest inward point within tolerance range.
- If point - 1 - has no gap, or if template cannot be brought into contact at point - 2 -, window frame is set too far inward and must be adjusted.
Height Adjustment at Window Frame
- If height of window frame must be adjusted, then the Bolts - 1 - must be replaced with a standard bolt.
- Now, the window frame height can be adjusted.
- Install the seals - 2 - and - 3 - into the window frame.
- Position adjusting template as shown on roof, or on upper edge of rain channel.
- Lower edge of window frame must be located within area - a - of template groove for a correct adjustment.
- Check/adjust inclination of window frame.
Front Door Adjustment
- Door position can be assessed using lower side of adjusting template (T40038/3) (illustration shows other template).
- No door recess in relation to side panel - 2 - is permitted.
- Recess of front door - 1 - to side panel - 2 - is not permitted (wind noise).
- Projection (maximum 0.8 mm) of front door to side panel must be in range of template cut-out - arrow -.
