Overhaul

Door Shell And Door Component Carrier, Removing And Installing







- Front door trim removed.

1 - Hex bolt
- 30 Nm (22 ft.lb.)
- Note tightening sequence
2 - Door shell
Removing:
- Disconnect harness connectors.
- Disconnect line for central locking system and unclip.

- Upper and lower hinges for door shell Fig. 1 and Fig. 2.
- Removing and installing side impact bar Fig. 4.







3 - Door component carrier.
Removing:
- Unclip Bowden cable for interior door mechanism.
- Disconnect harness connector for window regulator motor.
- Remove hex bolt - 1 - and - 5 - and lift out door component carrier.
Installing:
- Place door component carrier into door shell and loosely secure shorter hex bolts - 1 - and - 5 - at top.
- Insert adjusting plate - 4 - and tighten longer hex bolts - 1 - and - 5 - at bottom.

- Tighten hex bolts - 1 - and - 5 - in sequence a, b, c, d.
4 - Adjusting plate
- Must always be installed
- To adjust tilt of door around B-pillar, shift adjusting plate.
5 - Hex bolt
- 30 Nm (22 ft.lb.)
- Note tightening sequence

Fig. 1 Upper Door Hinge







1 - Tightening torque: 30 Nm (22 ft.lb.)
3 - Tightening torque: 30 Nm (22 ft.lb.)

Fig. 2 Lower Door Hinge







2 - Tightening torque: 30 Nm (22 ft.lb.)
3 - Tightening torque: 30 Nm (22 ft.lb.)

NOTE: Grease points (arrows) Fig. 3.

Fig. 3 Greasing Points For Lower Door Hinge







- Grease door check only at illustrated greasing points (arrows).
Grease: G 000 150

Fig. 4 Removing And Installing Side Impact Bar







- Pry off cover - 2 -.
- Remove hex bolts - 1 - (3x) and remove side impact bar - 4 -.

NOTES:
- Top part - 3 - and bottom part - 4 - are caulked to each other and must not be separated.
- Butyl cord - 5 - must always be installed; replace if necessary.