Door Assembly Front - II

Door Assembly Front







Pre-Repair Activities
Open door window half way before disconnecting battery.



Consumables
None.

Mechanical, Electrical and Trim, remove and install:
Door trim board (10 x clips, 3 x Pozidrive screws)
Door solid weather board (12 x T30 Torx screws)
Door window frame trim
Door mirror assembly (3 x 10 mm bolts)
Weather seal inner glass
Weather seal outer glass
Door drop glass front (1 x 10 mm bolt)
Door regulator mechanism (4 x 8 mm bolts, 1 x T30 Torx screw)
Door handle, lock/inner outer assembly (5 x T40 Torx screws)
Door check strap (2 x T30 Torx screws, 2 x 10 mm nuts)
Weather seals door outer
Door glass run felt Door front exterior trim (2 x Pozidrive screws)
Wiring Loom

MET Tools
Pozidrive screwdrive
8 mm socket
10 mm socket
3/8" Drive ratchet
Torx screwdriver
T30 torx bits
T40 torx bit
Suitable trim tool
Long nose pliers

Panel Tools
13 mm socket
3/8" drive ratchet
Torx screwdriver
T50 Torx bit
Torque wrench

01. The front door assembly is a category B bolt on panel.
Remove MET items as listed.
Complete 'Pre-Repair Activities'.







02. Split door hinges as shown (size T50 Torx bolt).

NOTE: Door supplied without hinges. If damaged, renew.







03. Remove upper and lower hinges from door assembly (4 x 13 mm nuts).
Fit hinges to new assembly as indicated (A/B).

NOTE: Bolts are pre-coated to inhibit galvanic corrosion and are reusable-only if coating is undamaged.







04. Fit and re-trim panel in reverse order.

Torque settings:
- Door to hinges (13 mm nuts) 30 Nm.

On completion of panel replacement, the following checks should be carried out:
1. Panel gaps (as indicated).
2. Hinge operation.
3. Lock alignment.
4. MET operation.