Overhaul
Assembling Rear Door Sub-frame
Tools
Assembling rear door sub-frame
Securing the support plate on the door frame
1. Affix 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. Secure the support plate on the door frame.
2.1. Place the support plate -2- (-2-) on the door frame -3- (-3-) and align it approximately.
2.2. Fix the support plate to the door frame using four rivets -4-. Rivet the rivets in the order -A, B, C, D-.
2.3. Rivet the joint areas between the support plate -2- (-2-) and door frame -3- (-3-) at the side (-5- or -5-). Hand riveting tool for pop rivets NR.124-1
Installing front and rear cover cap
1. Install front cover cap.
1.1. Attach front cover -6- to the door unit carrier using the locking tab and swivel to end position (-arrows-).
1.2. Rivet the front cover -6- to the door unit carrier (-8-).
2. Install rear cover cap.
2.1. Attach rear cap -7- to the door unit carrier using the locking tab and swivel to end position (-arrows-).
2.2. Rivet the rear cover -7- to the door unit carrier (-8-).
3. Insert expanding nuts.
3.1. Press in the expanding nuts -9- on the lower edge of the door unit carrier.
Installing the window seal
1. Install the window seal.
1.1. Lay out window seal -10- as shown and fit to the window frame in the top corner.
1.2. Place the plastic covers -11- and -12- (-arrow C- and -arrow D-) and push them against the corner area of the window seal (-arrow E- and -arrow F-).
1.3. Attach the window seal to the door frame along the B-pillar, roof rail, and C-pillar.
2. Install triangular cover.
2.1. Insert triangular cover -13- into the window seal-10- and clip it in -arrow G-.
3. Install inner window shaft moulding.
3.1. Position the inner window shaft moulding -14- in the front area (-arrow H-).
3.2. Centre the inner window shaft moulding -14- and press it evenly on to the door unit carrier over the entire length (-arrow I-).
4. Turn the component on the assembly table.
Installing the door seal
NOTE: When assembling the door unit carrier, as a general rule a new door seal must be fitted.
1. Fit door seal -15- to the door unit carrier in the front area.
2. The connection point -16- of the door seal must be in the marked area (-arrow J-).
3. Lay door seal -15- all round the door unit carrier and fit it. Take care no deformation or stretching occurs, especially in the area near roundings.
4. Check that door seal -15- is seated properly on door unit carrier.
5. Insert the grommet.
5.1. Push the grommet -16- into the door frame until it clicks into place.
Installing wiring harness
1. Lay wiring harness -17- on door unit carrier as shown.
2. Clip wiring harness -17- into the door unit carrier at the marked positions (-arrows A, D-).
3. Guide front area (transition to B-pillar) of wiring harness through the door unit carrier (-arrow E-) and pull it out to the front (-arrow F-). Make sure that the rubber grommet is not twisted when fitted
Completing and installing door lock
1. Completing the door lock.
1.1. Engage bowden cable -19- on door lock actuating mechanism and swivel by 90 degrees (-arrow G-).
1.2. Clip in fastening of bowden cable -20- on door lock -18- (-arrow H-).
1.3. Fit lock retaining bracket -21- (-arrow I-).
1.4. Rivet the lock retaining bracket -21- to the door lock -18- from the rear (-22-). Hand riveting tool for pop rivets NR.124-1.
Nozzle tips for hand rivet extractors NR.124-2
2. Clip in towing element.
2.1. Clip cable element -23- on to lever mechanism -24- (-arrow J-).
3. Install door lock.
3.1. Lay wiring harness -17- as shown.
3.2. Guide bowden cable -19- through the door unit carrier and insert door lock -18- (-arrow A-).
4. Rivet the door lock.
4.1. Insert electrical plug connections (-Pfeil B, C-) until they click audibly into place.
4.2. Insert the rivets -25- (-arrows D-) and rivet the door lock to the door unit carrier.
4.3. Position the cover -40- and clip it into place (-arrow F-).
Installing side window and power window mechanism
1. Install the power window mechanism.
1.1. Place the power window mechanism on the door frame as shown. Make sure the cable is in the correct position (-Arrow E-).
1.2. Clip in power window gear -26- in the door sub-frame.
1.3. Fix the guide rails -27- with 2 rivets each -28- and rivet to the door frame.
1.4. Apply lubricant (grease) to the guide rails and move the sliding pads -29- manually.
2. Insert door side window.
3. Installing the power window drive
3.1. Connect window power motor -32- and control unit -33- and clip into place.
3.2. Position the power window drive on the power window gear.
3.3. Screw in fastening screws -34- and tighten to tightening torque.
Tightening torque 2.0 ftlb. +/- 0.5 ftlb.
3.4. Connect push-on connectors -35-.
Installing holder, door unit carrier, and loudspeaker
1. Install holder.
1.1. Install holder for inside door handle -36-, insert fastening screws -37- and tighten with specified tightening torque.
Tightening torque 4.5 ftlb. +/- 0.5 ftlb.
2. Install rear door unit carrier.
3. Installing the loudspeaker
3.1. Position the loudspeaker -38- and rivet to the door unit carrier at the marked positions (-arrows-).
3.2. Connect electrical plug connection -39- (-arrow D-).