Removal and Replacement
Removing And Installing Rear Door Sub-frame
Preliminary work
1. Removing door handle
2. Remove rear door trim.
Removing rear door sub-frame
NOTE: When removing the rear door unit carrier, make sure that the door window is closed.
1. Remove rear assembly opening covers, detach lock mounting and KESSY wiring harness.
1.1. For all vehicles:
- unclip top and bottom assembly opening covers -1- and -2-.
- Unscrew fastening screws -3- on door lock.
1.2. Also for vehicles with KESSY control module:
- release the plug (-arrow A-) and take off (-arrow B-).
- Press out rubber sleeve (-arrow C-) and slide cable outwards through the opening.
2. Remove front assembly opening covers and disconnect electrical connection.
2.1. Unclip the top and bottom assembly opening covers -4- and 5-.
2.2. Pull off the rubber sleeve -7- between the doors and B-pillar.
2.3. Unlock and disconnect electrical plugs -6-.
3. Release door unit carrier.
3.1. Unscrew fastening screws for door unit carrier -8, 9- and 11-.
3.2. Press the rubber sleeve -10- inwards and push the plug connection back through the door aperture.
4. Remove door unit carrier.
4.1. Raise the door unit carrier -12- evenly at the front and rear until the guide pins -13- and -16- are fully released from the olding slots -14- and -15-.
4.2. Remove the door unit carrier from the basic door frame -17-.
Installing rear door sub-frame
1. Move adjustable fastening elements to their home position.
NOTE: The screw elements have left-handed threads.
1.1. Move the three adjustable fastening elements (-arrows A, B, C-) on the door unit carrier to their home position. Screw he screw element -19- fully into the basic element -18-.
2. Open basic door frame.
3. Engaging door unit carrier on basic door frame
3.1. Push the plug connection inward through the door aperture and press in the rubber sleeve -10- from inside into the door aperture.
3.2. Mount the door unit carrier -12- on the basic door frame 17-.
3.3. Insert guide pins -13- and -16- into the holding slots -14- and -15-.
4. Fix door unit carrier to basic door frame, link up electrical plug connection and tighten lock.
4.1. Fix the door unit carrier to the basic door frame by screwing in the fastening screws -9- and -11-. The fastening screws should only make light contact.
4.2. Connect electrical plugs -6-.
4.3. Press on the rubber sleeve -7- between the door and B-pillar.
4.4. Screw in new fastening screws -3- on the door lock and tighten to the specified tightening torque. Tightening torque 15 ftlb. -1.5 ftlb.
5. Adjust door unit carrier.
5.1. The fastening screw -11- secures the front bearing position (holding slot -15- for guide pin -16-). This bearing point cannot then be adjusted.
5.2. Close the door carefully.
NOTE: The figures showing the gap dimensions can be found in the section entitled.
5.3. The window frame (door unit carrier) must be adjusted with respect to the roof frame and B-pillar (-arrow D-). The pivoting points in this case are the holding slots -14-, -15- and the guide pins -13 - and -16-. Adjust the gap dimensions on the door unit carrier. Test and adjustment value 5 mm.
5.4. Tighten fastening screws -9, 11- to the specified tightening torque. Tightening torque 24 ftlb. +/- 2 ftlb.
6. Fasten door unit carrier.
6.1. Screw in fastening screws -8- and tighten to the specified tightening torque. Tightening torque 6 ftlb. +1.5 ftlb.
7. Clip in covers of front assembly openings.
7.1. Clip in the top and bottom assembly opening covers -4- and -5-.
8. Clip in rear assembly opening covers and connecting KESSY wiring harness.
8.1. For all vehicles:
clip in the top and bottom assembly opening covers -1- and -2-.
8.2. Also for vehicles with KESSY control module:
Pull KESSY wiring harness in through the opening. Install rubber sleeve in the unit carrier until it engages completely (-arrow A-). Insert plug into the socket (-arrow B-) until it clicks into place.
Subsequent work
1. Install rear door trim.
2. Install door handle.
3. Teach power windows.