Door Locks: Service and Repair

Changing the lock in a door

Preparations
- Roll the window all the way down.

Removing a door panel

Remove:
- the rubber mat in the door pocket
- the cover over screws in the handle
- the screws in the handle
- the frame round the inner door handle
- the panel over the door mirror attachment
- the clips in the door bottom (6)
- the clips in the side of the door (2)

Depress the securing plate in the bottom of the door pocket and withdraw the panel by the lower edge.

The panel is secured by 2 inside clips at front and rear.

Lift off the panel, starting at the rear.

Roll the window all the way up.

Dismantling switches

Dismantle the switches for
- speakers (1)
- power door mirrors (2)
- power windows (3)
- door locks (driver side only) (3)
- trunk (driver's side only) and fuel filler flap (driver's side only) (4)

Removing foam plastic

- Remove/bend aside foam plastic (1).

HINT: Use a plastic spatula to remove foam plastic.

- If the foam plastic breaks it must be changed.

Lock button, removing

Remove the lock button from the lock mechanism.

Wire, removing

- Remove the interior door handle (4 screws).
- Carefully bend the hook (5) out of the way and detach the wire end (1) from the interior door handle.

Measuring distance

- Measure and make a note of the distance (A) before removing the adjusting screw.
- Alternatively, you could count and note the number of turns needed when unscrewing the adjusting screw from the window frame.

Removing the rear lock nut

- Remove the lock nut from the adjusting screw. Use a torx driver as a counterstay.

Removing the rear adjusting button

- Unscrew the long part of the adjusting screw (3) from the window frame (1). Count the number of turns if you did not measure and note the distance (A).
- Press the window frame (1) against the outer panel of the door.
- Withdraw the short part (2) of the adjusting screw from the door panel.

Preparations for removing door handles and lock mechanism.

Remove:
- covers over screws (A)
- screws (B) for handles
- screws (B) for the lock mechanism. Do not unscrew the bottom screw fully yet.

Removing marker lights

- Move the marker light up and rotate it outwards.
- Unplug the connector.

Detaching the lead

- Detach the lead from the door panel.
- Pinch the clip (1) together and press it into the door.

Detaching door handles (earlier version)

- Remove the clip between handle and lock mechanism.
- Slightly withdraw the handle from the door.

NOTE: The handle must not come away at its joint (2). This applies throughout the method.

Detaching door handles (new version)

- The locking pin (1) on the driver side and the opening mechanism link (2) should have come away.

NOTE: The handle should not have come away at its hinge. This applies throughout the method.

Removing the lock cylinder on the driver side

- Slightly withdraw the handle from the door.
- Remove the cover (3). Start at (4). Pull straight out.

NOTE: Take care with painted surfaces.

- Prize out the clip (5) and press out the lock cylinder.

Removing the lock mechanism
- Push the lock wire into the door between the power window motor wire and inner door panel.
- Remove the screw (1).

NOTE: Do not lower the lock mechanism. Keep it where it is.

- Hold the lock mechanism when removing it from the door.

NOTE: If the wire is to be reused there must not be any sharp bends in it. This is important.

- Carefully lower the lock mechanism along the outer short side of the door until it reaches the bend at the bottom. Do not turn it.
- Press the window cassette against the door outer panel while pulling the lock mechanism along the bottom of the door towards the hinges.
- Unplug the 2 lock mechanism connectors.
- Rotate the lock mechanism opposite the opening in the door round the bottom part of the window cassette.
- Lift out the lock mechanism.

Fitting the lock mechanism

- Fit the wire and its rubber grommet in the door. Be careful not to damage the wire sheathing.
- Rotate the lock mechanism opposite the opening in the door round the bottom part of the window cassette.
- Lift the lock mechanism into place.

Plugging in the connectors

- Plug the connectors into the lock mechanism. Gray connector to (1) and black connector to (2).

Fitting the lock mechanism, cont.

- Press the window cassette against the door outer panel while pulling it along the short side of the door towards the exterior door handle.
- Carefully raise the lock mechanism along the outer short side of the door until it reaches the exterior door handle. Do not turn it.

NOTE: Do not lower the lock mechanism. Keep it where it is.

Fitting the screw

- Fit a new screw (B) and screw it in a few turns. The lock mechanism should not come away when it is being worked on but it should be so loose that it can be moved the maximum amount.

Fitting door handle (earlier version)

- Place the link (2) in front of the element on the lock mechanism (3).
- Carefully pinch together the element on the lock mechanism and the door handle link.

Fitting door handles (new version)

- Place the link (2) in front of the element on the lock mechanism (3).
- Fit a new screw in the lock mechanism. It should not be possible to move the lock mechanism by such an amount that the link (2) loses its grip on the element (3).

Fitting the lock cylinder on driver side (earlier version)

- Check that the hole in the lock mechanism intended for the locking pin is correctly positioned.
- Fit the lock cylinder and insert the locking pin (1) in the locking mechanism.
- Check that the lock cylinder is fitted firmly and correctly in place.
- Fit the cover over the lock cylinder.

Fitting the lock cylinder on the driver's side (new version)

- Press the door handle with lock cylinder hard against the body while fitting screws (A) and tightening them to 10 ±2.5 Nm.
- Check the operation of the lock without closing the door.
- Tighten screws (B) to 10 ±2.5 Nm.
- Fit the cover.

Fitting the lead

- Fit the clip (1) and press it home in the door.

Fitting marker lights

- Plug in the connector.
- Press the marker light into place.

Fitting the rear adjusting screw

- Press the window frame in the door (1) against the door outer panel.
- Insert the short part of the adjusting screw (2) in the door panel.
- Screw the long part of the adjusting screw (3) in the window frame in the door. Screw it in as many turns as you noted when removing it or to the measurement you noted when removing it.

Fitting the wire

- Press the wire end (2) onto the guide (3) before pressing the end of the wire sheathing (1) home in the door opening module. Make sure that the hook (5) engages properly.
- Remove cover (4) when the end of the wire sheathing (1) is fixed firmly in place.
- Check that the wire end (2) can run freely. Check the operation of the lock without closing the door.
- Fit the interior door handle.

Fitting the lock button

- Fit the lock button.

NOTE: Be careful to avoid damaging the plastic.

Fitting the foam plastic

- Fresh adhesive may be needed if the old foam plastic can be used. In such case use adhesive with part number 1161095.
- New foam plastic must be used if the old foam plastic is damaged. Damaged foam plastic must not be reused.

Plug in the connectors for

- speakers (1)
- power door mirrors (2)
- power window and door locks (3)
- trunk and fuel filler flap (4) Roll the window all the way down.

Fitting the door panel

- Fit the smaller molding present in the weather strip if this came loose when the panel was removed.
- Lift the panel into place.
- Make sure that the securing plate in the bottom of the door pocket fastens in the bracket.

Fit
- 2 clips in the side of the door
- 6 clips in the door bottom.
- the panel over the door mirror attachment
- the frame round the inner door handle
- the screws in the handle
- the cover over screws in the handle
- rubber mat in the door pocket

Check:
- the operation of the lock by closing and opening the door
- the operation of the lock by locking the door with the key and then with the remote control
- central locking from inside
- power windows
- door mirrors