Overhaul

Front Doors

Front 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.
- Disconnect harness connectors and unclip from door component carrier.
- Remove bolts - 3 -, - 9 -, - 6 - and - 4 - and lift door component carrier upward and out.







Installing:
- Front door - 5 - must be adjusted before installing door component carrier.

NOTE: Insert door component carrier into door, align with markings applied before removal and secure loosely.

- Install door component carrier and secure loosely with bolts - 3 -, - 4 -, - 6 - and - 9 -, and adjusting plates - 2 - and - 7 -.
- Shut door, check adjustment and readjust door component carrier as necessary.
- Repeat check and adjust if necessary.

CAUTION: Tighten bolts in the specified sequence: - 3 -, - 9 -, - 6 - and - 4 -.







2 - Adjusting plate

NOTES:
- The adjusting plate must always be installed.
- Inclination of front 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 - Front door

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

- Remove bottom section of A-pillar trim.
- Disconnect harness 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 T45 Torx bolts securing upper and lower hinges to door and remove door complete with door component carrier.
- Panel gaps.
6 - Bolt w/washer assembly
- 30 Nm (22 ft lb)







7 - Adjusting plate

NOTES:
- The adjusting plate must always be installed.
- The inclination of the door component carrier at the B-pillar can be adjusted by altering the position of adjusting plate - 7 -.
- If an adjustment plate has insufficient adjustment range, install a suitably sized washer.
- Do not use two adjusting plates together.

8 - Washer
- Self-adhesive
9 - Bolt w/washer assembly
- 30 Nm (22 ft lb)







Fig. 1 Upper door hinge
1 - Bolt (installed from inside vehicle) (30 Nm or 22 ft lb)
2 - Upper door hinge
3 - Torx(R) bolt (30 Nm or 22 ft lb)
4 - Bolt (installed from inside vehicle) (30 Nm or 22 ft lb)
5 - Stud
Tightening torque: 23 Nm (17 ft lb)
6 - Cap - 6 - for stud - 5 -







Fig. 2 Lower door hinge
1 - Lower door hinge
2 - Bolt (30 Nm or 22 ft lb)
3 - Front door
4 - -Bolt (30 Nm or 22 ft lb)
5 - Torx(R) bolt (30 Nm, or 22 ft lb)