Removal and Replacement
Components front side door, replacing
Note! The illustrations in this service information are used for different model years and / or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Caution! Always use battery back-up in the event of long adjusting times.
Note! When replacing the lock unit only: Changing the lock in a side door Service and Repair
Door panel
Door panel
- Remove the screw in the handle
- Use a screwdriver with a 10 mm wide tip. Bend the tip to an angle of 90°
- Detach the surround in the order illustrated
- Pry off surround carefully by pressing clips in towards center of surround and carefully pulling outwards using the bent screwdriver.
Note! Protect the door panel.
Remove:
- the door mirror panel
- the 6 press clips at the bottom edge of the door
- the 2 press clips in the side of the door.
Depress the lock facing at the bottom of the center console locker. Pull out the bottom edge of the panel.
Lift out the panel. Start at the rear edge of the panel. The panel is secured using 2 internal clips at the rear and front edges.
The weatherstrip may come with the panel on removal. Remove the smaller molding in the weatherstrip.
Press the control panel for the power window mechanism upwards by hand from the inside.
Disconnect the connectors.
New replacement part panel on the driver's side
The replacement part panel does not have a cut-out for the power mirror control. It only has an embossed section on the reverse of the panel. Carry out the following:
- The cut-out for the power mirror control must be 23.5x29 mm
- Cut the rear of the cardboard along the perforations using a small sharp knife.
Caution! First cut through the cardboard in the panel, from the reverse through to the leather / textile surface material.
- Remove the cut out cardboard
- Cut through the textile / leather surface material from the reverse of the panel.
Installation
If the weatherstrip came out with the panel on removal, install the smaller molding on the upper member for the door cassette before installing the weatherstrip.
The smaller molding should start approximately 15 cm from the rear edge of the door towards the door mirror.
Hint: It is easier to install the molding if it is lubricated using soap solution.
Equipment on and in the door
Mirror
Remove the door mirror.
To disassemble the door mirror see Door mirror Removal and Replacement.
Replacing the cassette for the front power window lift mechanism
Removing the front power window lift mechanism cassette
Note! Mark the horizontal and vertical positions of the power window lift mechanism cassette at the front and rear edges.
Note! Check if the mounting screws have washers between the inner panel and the power window lift mechanism cassette. If this is the case, count the washers. Install the same number of washers for each mounting screw as were removed from between the inner panel and the power window lift mechanism cassette.
Note! The window must be up to lift out the cassette. If the window is in the down position, because of a faulty motor or mechanical cable, the mechanical cable directly connected to the motor must be cut off. To replace the motor and mechanical cable. Replacing the lift mechanism motor and mechanical cable for side window .
Note! The front adjustment screw must not press into the guide rail.
Remove:
- the connector
- 5 screws for the loudspeaker
- 4 screws (C) for the inner door opener
- the soundproofing panels.
Hint: Scrape off the soundproofing mats using a plastic filler spatula.
- 1 nut (D) and 1 screw (E) from the lock bracket
- the connector and the remaining nuts (D) for the lift mechanism motor
- the remaining SIPS block screws (E) in the bottom edge of the door.
Lift out the outer SIPS block
- the lock nuts (A) on both adjustment screws. Counterhold using a torx screwdriver. Screw in both adjustment screws as far as they will go.
Note! The front adjustment screw must not press into the guide rail. Screw in lightly by hand until it engages.
- 6 screws (B) and (F) in the upper edge of the door securing the cassette in the door.
Lift out the power window mechanism cassette.
Caution! Take care not to damage the door panels when lifting the cassette out of the door. It is easier if two people lift the cassette.
A new reinforced bracket and new tolerance compensator has been introduced on the power window lift mechanism cassette for:
- Convertible, left-hand side from chassis number 013076
- Convertible, right-hand side from chassis number 013054.
Installing the front power window lift mechanism cassette
Note! When installing a new cassette on an existing door, the holder on the tolerance compensator (1) must be cut off.
Hint: Hold the compensator in place using pliers while securing it by screwing it out.
Install the tolerance compensator.
Note! Slide the cassette as far forward as possible. Failure to do so may result in leakage.
Thread 2+1 screws into the rear edge of the cassette / door (B).
Note! Locking fluid must be applied to the rear center screw (F).
Thread two screws into the front edge of the cassette / door (B).
Tighten the front upper screw (B).
Tighten the rear upper screw (B).
Press in the screw in the tolerance compensator.
Thread and tighten the screw so that the tolerance compensator fills the gap between the cassette and the door.
Tighten the rear lower screw (B).
Adjusting the side door
Adjust the side door. See Side door front assembly, adjusting Side Door Front Assembly, Adjusting.
Soundproofing panel
In order for the audio system to retain high sound quality and minimize road noise it is important that the soundproofing mats in the doors are complete and properly bonded to the doors.
Caution! If a soundproofing panel is damaged, it must be replaced.
Adjusting window in front power window lift mechanism cassette
Adjust the window in the front power window lift mechanism cassette. See Window front side door, adjusting Window Front Side Door, Adjusting.
Removing rear power window lift mechanism cassette
Caution! The lift mechanism motor must not be operated when the mechanical cables are not tensioned. The mechanical cables could get tangled in the motor.
Note! Raise the rear side window to its highest position.
Remove:
- the rear seat. See Rear seats Rear Seats
- the rear side panel. See Panels Panels
- the sound insulation in front of the lift mechanism motor.
Disconnect the connector on the electric motor. Lift and pull to the side.
Remove:
- 4 screws for the cover plate.
Note! Carefully lift out the cover plate with the inner weatherstrip. Do not scratch the paint work.
- the two front nuts. Remove the two rear nuts for the power window lift mechanism cassette.
Note! The screws for the power window lift mechanism cassette are also adjustment screws.
Carefully lift up the power window lift mechanism cassette.
Window in the rear power window lift mechanism cassette
Place the power window lift mechanism cassette on the workbench.
Note! Protect the glass when working on the workbench.
Remove the 3 screws for the window in the power window lift mechanism cassette.
Note! Do not move the end stops.
Installing the rear power window lift mechanism cassette
Install:
- the power window lift mechanism cassette carefully
- the two front nuts. Tighten the two rear nuts for the power window lift mechanism cassette
- the connector for the electric motor
- the screws for the cover plate (4).
Note! The screws for the power window lift mechanism cassette are also adjustment screws.
For other adjustment of the rear side window, see Side window rear, adjusting Side Window Rear, Adjusting.
- the sound insulation in front of the lift mechanism motor
- the side panel. See Panels Panels
- the rear seat. See Rear seats Rear Seats.
Door handle, lock unit and lock cylinder
Remove the clip between the handle and lock unit using a screwdriver. Press as illustrated.
Installation
Press the clip into place in the handle using your fingers.
The screws (A) are for the handle.
Screws (B) are for the lock unit.
Lock cylinder
Remove the handle from the door.
Lift the lock facing.
Press out the lock cylinder from the reverse. The key is not required to do this.
Caution! The key must not be in the lock during installation. The lock cylinder may be installed incorrectly if the key is in the lock.
Lock unit
Remove:
- the 2 screws for the inner door opener
- the 2 connectors
- the mechanical lock cable from the lock as illustrated.