Service Manual
ADJUSTMENT
Door Position
WARNING: Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof. When moving components, ensure that no body parts or limbs are within the operating range of moving parts.
NOTE: Door adjustment measurements should be taken from stationary or welded body panels like the roof, rocker or quarter panels.
1. Check gaps on rear end door all the way around.
2. Loosen the mounting screws (2).
3. Loosen the mounting screws through the hole (1) in the hinge.
4. Adjust the rear end door and tighten the mounting screw (1) to 23 Nm (17 ft. lbs.).
NOTE: The door hinge pins (3, 4) should be aligned with one another, otherwise the doors are hard to move and the hinges can make noises.
5. Tighten screws (2) to 23 Nm (17 ft. lbs.).
6. Adjust the closing system on the rear end doors, refer to Latch Adjustment.
7. Check the rear doors for ease of movement.
8. Finish paint in adjustment range of hinges on the rear pillars using brush.
NOTE: Since the hinges are already installed on the body shell at the factory it is not possible for corrosion protection agent to adhere to the contact surfaces. The unprotected areas must therefore be touched up after adjustment.
Latch Adjustment
Adjust left rear-end door
1. Loosen the bolts and door latches at the top and bottom and locking eyes with guide punch at the top and bottom.
Adjust bottom door latch
2. Align the guide pin in the center in relation to the guide and fasten in outermost position.
3. Close the rear-end door.
4. Tighten the bolts on the bottom door latch (1) to 10 Nm (90 in. lbs.).
5. Loosen the bolts (2) on the locking eye (1) with the guide pin and adjust the door flush.
6. Tighten the locking eye with guide pin bolts (2) to 20 Nm (15 ft. lbs.).
Adjust upper door latch
7. Align guide pin in center in relation to guide and fasten in outermost position.
8. Close rear-end door.
9. Tighten bolts (1) on upper door latch (2) to 10 Nm (90 in. lbs.).
10. Loosen locking eye with guide pin (1) and adjust door flush in relation to roof.
NOTE: Have second person check door flushness with roof panel.
11. Tighten locking eye with guide pin bolts (2) to 20 Nm (15 ft. lbs.).
Adjust right rear-end door
12. Loosen bolts on upper door latch and upper/center locking eyes as well as guide punch.
Adjust center door latch
13. Loosen bolts 2) on center door latch locking eye (1).
14. Align center door latch locking eye in center and faster.
15. Close doors
16. Adjust locking eye until right rear-end door is flush with left rear-end door.
NOTE: Locking eye must engage in center of lock. Do not lift or pull down door.
17. Tighten locking eye bolts to 20 Nm (15 ft. lbs.).
Adjust guide punch
18. Mark guide pin (2) at dimension A.
19. Close rear-end door.
20. Adjust marking on guide pin flush with end of guide and tighten guide pin bolts (1) to 20 Nm (15 ft. lbs.).
Adjust upper door latch
21. Align guide pin in center in relation to guide and fasten in outermost position.
22. Close rear-end door.
23. Tighten bolts (1) on upper door latch (2) to 10 Nm (90 in. lbs.).
24. Loosen locking eye with guide pin (1) and adjust door flush in relation to roof.
NOTE: Have second person check door flushness with roof panel.
25. Tighten locking eye with guide pin bolts (2) to 20 Nm (15 ft. lbs.).
Adjust door latch normalization
26. Open left rear-end door.
27. Close door latch at top and bottom.
28. Loosen bolts on rear-end door inner lock (1).
29. Slowly actuate door opener (3) until bottom door lock opens.
30. Hold door opener in this position.
31. Turn adjusting screw (2) until upper bolt releases.
32. Tighten rear-end door inner lock to 8 Nm (71 in. lbs.).