Removal and Replacement

Door Shell And Door Component Carrier, Removing And Installing

NOTE: Upper and lower hinges for door shell Fig. 1 and Fig. 2.

- Rear door trim removed







1 - Door component carrier
Removing:
- Unclip Bowden cable for inside door mechanism.
- Disengage Bowden cable for door lock and unclip.
- Disconnect harness connector for window regulator motor.
- Remove hex bolts - 3 - and - 4 - and lift out door component carrier.
Installing:







- Place door component carrier into door shell and loosely secure shorter hex bolts - 3 - at top.
- Insert adjusting plate - 2 - and tighten longer hex bolts - 4 - at bottom.
- Tighten bolts - 3 - and - 4 - in sequence a, b, c, d
2 - Adjusting plate
- Must always be installed
- To adjust tilt of door around B-pillar, shift adjusting plate
3 - Hex bolt
- 30 Nm (22 ft.lb.)
- Note tightening sequence
4 - Hex bolt
- 30 Nm (22 ft.lb.)
- Note tightening sequence
5 - Bowden cable for inside door mechanism
6 - Bowden cable
- For locking door

Fig. 1 Upper Door Hinge







4 - Tightening torque: 30 Nm (22 ft.lb.)
5 - Tightening torque: 30 Nm (22 ft.lb.)

Fig. 2 Lower Door Hinge







4 - Tightening torque: 30 Nm (22 ft.lb.)
5 - Tightening torque: 30 Nm (22 ft.lb.)

NOTE: Greasing points Fig. 3.

Fig. 3 Lower Door Hinge Greasing Points







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

Fig. 4 Removing Side Impact Bar







- Pry off cover - 3 -.
- Remove hex bolts - 2 - (3x) and remove side impact bar - 5 - from door shell- 1 -.

NOTE: Butyl cord - 4 - must always be installed; replace if necessary.