Front Door: Testing and Inspection

Checking Door Adjustment With Template T40038/4

Special Tools, Testers And Auxiliary Items Required
- Template T40038/4







- Use the template T40038/4 as described in the following for testing (e.g. 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 - = 160 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 window frame height must be adjusted, fitting screws - 2 - and - 5 - must be replaced with a standard screw of same strength and length.







- Window frame - 1 - can now be adjusted in height to door - 4 -.
- Gaskets - 2 - and - 6 - slid into 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 T40038/4 (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 -.