Overhaul

Disassembling And Assembling Door







Disassembling door

WARNING: Danger of injury if side airbag units in the door are triggered while ignition key is not removed.
- Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed.
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair.

CAUTION: Damage to the bowden cable when removing door trim panel. Damage by bending the bowden cable at the hook.
- Pull the hook out of the end piece only after installation in the inner door release.

CAUTION: Damage to plug connection lugs during door removal. Damage to lugs when pulling the plug connection out of the A-pillar.
- The locking element at the bottom part of the plug connection must be pulled out before the plug connection is disconnected.

CAUTION: Danger of material damage if the door lock is installed incorrectly. Malfunctions in the alarm system.
- The door lock should be installed only when the actuating lever is in basic position.

INFORMATION:
- The door trim panels must be removed before removing the parts inside the door. Refer to Removing and installing door trim panel.
- Follow the special instructions on installation and adjustment for assembly of the door. Refer to Adjustment instructions for assembly of the door.

1. Remove mount







1.1. Undo the M6 x16 hexagon-head bolt and remove the mount.

2. Unclip and disengage the bowden cable







2.1. Disengage support frame -arrow A- upwards.
2.2. Unclip bowden cable -arrow B- from the door lock.
2.3. Swivel bowden cable by 90 degrees -arrow B- and pull it out of the actuating lever -arrow D-.

3. Disconnect connection piece







3.1. Move connection piece -A-.
3.2. Press -C- downwards.
3.3. Press the connection piece -B- upwards and separate from each other.

4. Remove door handle and bottom part of door







4.1. Remove collar nuts M6.
4.2. Separate bottom part of door handle from door handle and remove.
4.3. Press electrical plug connection off microswitch -A- and disconnect.
4.4. Unclip on the base of the electrical lead -B-.

5. Remove door lock







5.1. Undo micro-encapsulated Torx screws T40 M8 x 14.
5.2. Disconnect the electrical plug connection. To do this, press the locking lug -A- on the plug connection and separate in the direction of the arrow -B-.
5.3. Pull door lock with actuating motor unit out of the door.

6. Remove door window







6.1. Undo Torx screws T 30 on the clamping pieces of the power window unit.
6.2. Pull door window out of the door channel.

7. Remove power window unit







7.1. Disconnect the electrical plug connection.
7.2. Undo collar nuts M6 from the power window unit.
7.3. Pull the power window unit downward out of the door opening.

8. Remove door brake







8.1. Unscrew Torx screw M8 -A- from the A-pillar.
8.2. Remove collar nuts from the door brake.
8.3. Pull out the door brake towards the inside.
8.4. Remove the seal.

9. Remove door seal on outside







9.1. Press out clip -A- with a plastic spatula.
9.2. Pull off door seal on the outside.
9.3. Carefully pull the seal out of the clips along the door contour.

10. Remove window guide rail







10.1. Unscrew the B3.5 x 9.5 sheetmetal screw from the window guide rail.
10.2. Pull off the B 3.5 sheetmetal nut.

11. Remove door channel seal on inside







11.1. Pull the door channel seal on the inside off the bead of the door channel.

12. Remove lid







12.1. Press out the 24 x 40 lid -A- and the 20 x 28 lid -B- with a plastic spatula.

13. Remove wiring harness







13.1. Unclip the electrical wiring along the inner door panel.
13.2. Pull wiring harness out of the door in the -direction of the arrow-.

14. Remove angle piece







14.1. Unscrew T 45 M8 x 33 Torx screw from the angle piece and the 12 x 8 x 7 centering sleeve.

Assembling door

INFORMATION:
- The bottom edge of the window must rest on the screw during adjustment.
- Observe additional instructions for adjusting the door window.

WARNING: Danger of injury if side airbag units in the door are triggered while ignition key is not removed.
- Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed.
- The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair.

INFORMATION:
- Follow the special instructions on installation and adjustment for assembly of the door.
- In order to achieve better adhesion, heat the insulation using a hot-air gun.

1. Stick in the insulation







1.1. Peel off the backing and stick the insulation into the door below the side-impact bar.

2. Fit angle piece







2.1. Position the angle piece with the 12 x 8 x 7 centering sleeve on the door and fasten with the T 45 M8 x 33 Torx screw.
2.2. Tightening torque: 23 Nm (17 ftlb.)

3. Fit wiring harness







3.1. Insert wiring harness into the door in the -direction of the arrow-.
3.2. Clip in the electrical wiring along the inner door panel.

4. Fit lid







4.1. Press in the 24 x 40 lid -A- and the 20 x 28 lid -B-.

5. Fit door channel seal on inside







5.1. Position the door channel seal on the inside -arrow- in the bead of the door channel and press it on.

6. Fit window guide rail







6.1. Push on the B 3.5 sheetmetal nut.
6.2. Position the window guide rail and fasten it with the B3.5 x 9.5 sheetmetal screw.
6.3. Tightening torque: 1.4 Nm (1 ftlb.)

7. Fit door seal on outside







7.1. Position door seal on the outside at the top edge of the door and push it on.
7.2. Clip in the seal along the door contour.
7.3. Fasten the door seal on the inner door panel with the clip -A-.

8. Fitting door brake







8.1. Position the seal.
8.2. Insert door brake from the inside and fasten it with the collar nuts.
8.3. Tightening torque: 10 Nm (7.5 ftlb.)
8.4. Screw Torx screw M8 -A- onto the A-pillar.
8.5. Tightening torque: 23 Nm (17 ftlb.)

9. Fit power window unit







9.1. Insert power window unit into the door opening from below.
9.2. Fasten the power window unit with the M6 collar nuts.
9.3. Tightening torque: 10 Nm (7.5 ftlb.)
9.4. See: Additional adjustment instructions for the power window.
9.5. Plug in the electrical plug connection.

10. Fit door window







10.1. Insert door window into the door channel and position it in the front and rear clamping pieces of the power window unit.
10.2. Tighten the T 30 Torx screw.
10.3. Tightening torque: 8.5 ± 1.5 Nm (6.0 ± 1.0 ftlb.)

INFORMATION:
- The actuating lever must be locked in basic position before installation.
- Observe additional instructions for adjusting the door lock.

11. Fit door lock







11.1. Insert door lock with actuating motor unit into the door and fasten with the micro-encapsulated T40 M8 x 14 Torx screw.
11.2. Tightening torque: 20 + 2 Nm (15.0 + 1.5 ftlb.)
11.3. Plug in the electrical plug connection.

12. Fit connection piece







12.1. Clip in the electrical lead -B- on the base.
12.2. Insert door handle and position the bottom part of the door handle on the door handle from inside. Tighten with the collar nuts M 6.
12.3. Tightening torque: 10 Nm (7.5 ftlb.)
12.4. Connect electrical plug connection -A-.

13. Disconnect connection piece







13.1. Insert the connection piece into the actuating shaft -arrow A- without play.
13.2. Push out the sliding piece -arrow B- until it can be heard to engage.
13.3. Actuate the handle -arrow C- to ensure that the handle and door lock function without play.

14. Fit bowden cable







14.1. Insert bowden cable into the actuating lever -arrow D- and rotate by 90 degrees -arrow C-.
14.2. Clip bowden cable into the door lock -arrow B-.
14.3. Engage support frame -arrow A- on the door lock.

15. Fit mount







15.1. Position the mount in the door and fasten it with the M6 x 16 hexagon-head bolt.
15.2. Tightening torque: 10 Nm (7.5 ftlb.)