Front Door: Service and Repair

Front door assembly:

Window Frame Assembly:

Door Lock, Lock Rod, Lock Cylinder, Assembly:

Door Handle:

Fig. 1 - Front door, removing/installing



Removing
^ remove hex head bolts (arrows)
Installing
Install in reverse order, note the following:
^ install hex head bolts, 30 Nm (22 ft lb)


Fig. 2 - Lower door hinge, lubrication



^ apply lubricant AOS 126 000 05 or equivalent to points shown


Door slot molding, removing/installing
Removing
^ pry out from top of door shell
Installing
^ clean molding channel with 3M General Purpose Adhesive Cleaner or equivalent
^ place 3.0 mm (1/8 in.) bead of AKD 476 KD 505 into molding channel
^ position molding onto door shell
^ press molding into place


Fig. 3 - Carrier for door components, removing/installing



Removing
^ remove front door trim panel Service and Repair
^ remove Bowden cable from inner door opening mechanism
Installing
Install in reverse order, note the following:
^ check door shell adjustment, adjusting, Fig. 15
^ adjust door component carrier support, Fig. 18
^ torque hex head screws (arrows) 20 Nm (15 ft lb)


Fig. 4 - Adjusting window in carrier



^ section A-A
^ adjust window stop from window lifter 1
^ contact area B of window to inner window weatherstrip


Fig. 5 - Adjusting window glass



^ adjust window glass with door closed
^ adjust upper stop of window regulator so inner sealing lip 2 in area B (see Fig. 4) contacts upper edge of window
a = 0.5 mm (1/32 in.)

Note: A minimum pre-load of 0.5 mm (1/32 in.) when sealing lip 2 contacts window will eliminate leaks.


Fig. 6 - Plugs



^ insert into window guide from below
a 65 mm (2.6 in.)
^ measured from end of window channel

Note: The plug is used as a seal and an anti-noise measure.


Fig. 7 - Window regulator, removing/installing



Removing
^ remove carrier for door components, Fig. 3
^ remove lock washer 2
^ remove mounting washer, buffer
^ pull out window from window lifter bolt
^ bend clip 7 in direction of arrow and press Bowden cable out of clip
^ unscrew hex head nuts 6
^ unscrew hex head bolts 16
Installing
Install in reverse order, note the following:
^ install hex head bolts
^ 6 Nm (5 ft lb)
^ place buffers between window and carrier
^ check and adjust window if necessary, Fig. 4, 5


Fig. 8 - Door lock, removing/installing



Removing
^ remove front door trim Service and Repair
^ release operating rod clip and pull out operating rod
^ unhook bowden cable
^ pull out door lock from part 2
^ remove seal 3
Installing
Install in reverse order. Note the following:
To re-hook bowden cable, pull lever 4 in direction of arrow. insert screwdriver into hole 5 to lock cable into place.
^ torque all bolts to 16 Nm (12 ft lb)


Fig. 9 - Lock operating rod, removing/installing



Removing
^ place bushing into operating rod 2
^ put operating rod 3 into lever
^ insert mounting clip 4 into door lock release lever
^ check operating rod free play in clip 4, without putting undue strain on the door lock release lever
^ 1.0 mm (3/64 in.) maximum free play
Installing
install in reverse order.
^ to adjust move sleeve upwards on operating clip 4


Fig. 10 - Replacing inner door lock bowden cable



Removing
^ remove door trim Service and Repair
^ unclip bowden cable
^ pull bowden cable and lock door lock with screwdriver, Fig. 8
^ unhook bowden cable (arrow)
Installing
Install in reverse order.
^ note how bowden cable is placed in clips


Fig. 11 - Turn clip, installing



A = lock clip tight in locked position
B = lock clip released
^ indentation 1 in lock clip must line up


Fig. 12 - Position spring, installing



Note: When tensioned, the ends of the spring 1 must be positioned to left and right of operating lever 2.

Pre-tensioning always pushes the operating lever and lock cylinder into center position.


Doors, adjusting



^ adjust gap by moving doors with hinges - Fig. 13,14
a = 5 + 1 mm (13/64 + 3/64 in.)
b = 5.5 + 1 mm (7/32 + 3/64 in.)
^ align height with contour of body Adjust at hinges (extra-large holes in hinge at the point where hinge fastens to A/B pillar) Fig. 15
^ to prevent to wind noises, adjust at door mounting hinges or in rear of doors at striker pin, Fig. 16,17
Section A-A. B-B, C-C:
C = 0.5 + 0.5 mm (1/64 + 1/64 in.)
Section D-D:
d = 14.5 mm (9/16 in.)


Fig. 13 - Door gap, adjusting



^ with bolts 1 removed, screw out threaded bushing behind until it no longer contacts A-pillar
^ loosen bolts 2, close door and adjust gap by moving the door
a = 5 + 1 mm (13/64 + 3/64 in.)
^ loosen or tighten with angle wrench US 2598


Fig. 14



^ screw in threaded bushing 3 until it makes contact with A-pillar
^ screw in bolts and tighten to 30 Nm (22 ft lb)
^ check gap


Fig. 15 - Height adjustment



^ loosen bolts 1, 2
^ loosen or tighten with angle wrench US 2598
^ move door with hinge
^ tighten bolts
^ 30 Nm (22 ft lb)


Fig. 16



^ loosen bolts (arrows), move door as required
^ tighten bolts
^ 30 Nm (22 ft lb)


Fig. 17 - Prevention of wind noises



^ adjust the striker pins at the rear of the door
^ striker pin 50 Nm (37 ft lb)
1 = striker pin
2 = dished washer
3 = washer

Note: If necessary, two dished washers can be used.


Fig. 18 - Door component carrier, adjusting




Note: Window and door shell must be adjusted first.

^ loosen bolts (arrows)
^ close door

Two technicians will be required. Do not press door shell inwards while performing adjustment.
^ press carrier tightly against root and pillar
^ exert slightly more force than required. Rubber seal will return carrier to proper position
^ have second technician (from inside vehicle) tighten first upper then lower bolts
^ 20 Nm (15 ft lb)


Fig. 19 - Door component carrier dimensions



^ left door cross section shown
^ the outer sealing lip 7 must make contact along the contour of the pillar and roof trim moulding 3
^ the outer window sealing lip 8 must not project outwards above the root trim moulding 3
c = 3.5 + 1 mm (9/64 + 3/64 in)
d = 8.1 + 1 mm (5/16 + 3/64 in)
1 - sealing flange
2 - door frame
3 - roof trim moulding
4 - window
5 - window seal
6 - inner door seal
7 - seating lip
8 - sealing lip on window