Front Door: Service and Repair

Assembling Front Door Sub-Frame

Tools







Assembling front door sub-frame












1. Affixing foam seal to the rear of the support plate
1.1. Clean marked area -1- on the support plate -2-. The area must be completely free of any greasy residues.
1.2. Stick self-adhesive foam seal in the marked area -1-. The foam seal must not be deformed or stretched in the process.



























2. Securing the support plate on the door frame
2.1. Place the support plate -2- on the door frame -3- and align it roughly.
2.2. Fix the support plate to the door frame using four rivets -4-. Rivet the rivets in the sequence -A, B, C, D-. Hand riveting tool for pop rivets NR.124-1Nozzle tips for hand rivet extractors NR.124-2
2.3 Rivet the joint areas between the support plate -2- and door frame -3- at the side -5-. Hand riveting tool for pop rivets NR.124-1Nozzle tips for hand rivet extractors NR.124-2












3. Installing front cover cap
3.1. Attach the front cover cap -6- to the door sub-frame using the locking tabs and clip it in.






















4. Installing rear cover cap
4.1. Attach rear cap -7- to the door sub-frame using the locking tab and swivel to end position (-arrows-).
4.2. Rivet the rear cover -7- to the door sub-frame -8-.












5. Inserting expanding nuts
5.1. Press in the expanding nuts -9- on the lower edge of the door sub-frame.












6. Installing inner window shaft moulding
6.1. Position the inner window shaft moulding -10- in the front area (-arrow A-).
6.2. Centre the inner window shaft moulding -10- and press it evenly on to the door sub-frame over the entire length (-arrow B-).












7. Installing the window seal
7.1. Lay out window seal -11- as shown and fit to the window frame in the top corner.
7.2. Insert the plastic cover -12- (-arrow C-) and push it against the corner area of the window seal (-arrow D-).
7.3. Attach the window seal to the door frame along the B-pillar, roof rail, and A-pillar.

8. Turning the component on the assembly table.












9. Installing the door seal
9.1. Fit door seal -13- to the door sub-frame in the front area.
9.2. The connection point -14- of the door seal must be in the marked area (-arrow E-).
9.3. Lay door seal -13- all round the door sub-frame and fit it. Take care not to deform or stretch the seal, especially in rounded areas.
9.4. Check that door seal -13- is seated properly on door sub-frame.







10. Inserting the grommet
10.1. Push the grommet -15- into the door frame until it clicks into place.

















11. Installing wiring harness
11.1. Lay wiring harness -16- on door sub-frame as shown.
11.2. Clip wiring harness -16- into the door sub-frame at the marked positions (-arrows A - F-).
11.3. Guide front part (transition to A-pillar) of wiring harness through the door sub-frame (-arrow G-) and pull it out to the front (-arrow H-). Make sure that the rubber grommet is not twisted when fitted.












12. Completing the door lock
12.1. Engage bowden cable -18- on door lock actuating mechanism and swivel by 90 degrees (-arrow I-).
12.2. Clip in fastening of bowden cable -19- on door lock -17- (-arrow J-).
12.3. Fit lock retaining bracket -20- (-arrow K-).
12.4. Rivet the lock retaining bracket -20- to the door lock -17- from the rear (-21-).

















13. Clipping in cable element
13.1. Clip cable element -22- on to lever mechanism -23- (-arrow L-).







14. Installing door lock
14.1. Lay wiring harness -16- as shown.
14.2. Guide bowden cable -18- through the door sub-frame and insert door lock -17- (-arrow A-).






















15. Riveting the door lock
15.1. Insert electric plug connections (-arrows B, C-) until they click audibly into place.
15.2. Insert the rivets -25- (-arrows D-) and rivet the door lock to the door sub-frame.
15.3. Position the cover -40- and clip it into place (-arrow F-).

















16. Install the power window mechanism.
16.1. Place the power window mechanism on the door frame as shown. Make sure the cable is in the correct position (-arrow E-).
16.2. Clip in power window gear -26- in the door sub-frame.
16.3. Fix the guide rails -27- with 2 rivets each -28- and rivet to the door frame.
16.4. Clip in the fixing clip -29- in the door sub-frame and attach the cable.
16.5. Apply lubricant (grease) to the guide rails and move the sliding pads -30- manually.












17. Stick on insulating material -33-.

18. Install door glass.












19. Installing the power window drive
19.1. Connect window power motor -34- and control unit -35- and clip into place.
19.2. Position the power window drive on the power window gear.
19.3. Screw in fastening screws -36- and tighten to the specified tightening torque.
Tightening torque 2 ftlb. +/- 0.1 ftlb.

19.4. Connect electric plugs -37-.

20. Installing the door sub-frame







21. Installing the loudspeaker
21.1. Position the loudspeaker -38- and rivet to the door sub-frame at the marked positions (-arrows-).
21.2. Connect electric plug connection -39- (-arrow D-).

Removing cover for front window guide







1. Press bottom window guide to one side.
1.1. Press the window guide at the bottom corner of the cover to one side.







2. Unclip cover at lower edge from the door sub-frame.







3. Press top window guide to one side.
3.1. Press the window guide at the top corner of the cover to one side.







4. Unclip cover at top edge from the door sub-frame.







5. Remove cover.


Installing cover for front window guide












1. Position cover.
1.1. Push in cover into the corner of the door sub-frame below the window guides.







2. Engage cover.
2.1. Press in the cover into the corner of the door sub-frame until the cover is felt to engage.
2.2. Check that sealing lip is fitted correctly.