Front Door: Service and Repair

Crank window
open.
Panelling (1) at side in footwell
remove; press off cover (2) and screw out screw.
Retaining strap on plug connection at side of footwell
pull out.
All electrical and pneumatic lines for driver's door
disconnect at plug connection.
Bolt (3) on door retainer
remove.
Protective hose (4)
unclip at A-pillar.
Bolts (arrows)
screw out of A-pillar (4 each); have second person hold driver's door to keep it from falling (37 Nm).
Driver's door (5)
remove from centering bolts (2 each) on A-pillar toward rear, simultaneously guide electrical and pneumatic lines through A-pillar. Avoid damage to paint!
Reinstall
in opposite order.






Special tool

Installation and adjustment







1 Position door with hinges on centering bolts; simultaneously insert pneumatic and electrical lines through A-pillar.







2 Screw in mounting bolts (4 each) and tighten (37 Nm).







3 Clip or fasten protective hose and door retainer to A-pillar.







4 Connect all lines for driver's door at plug connector in footwell and lock with retaining strap.
5 Install panelling in footwell.
6 Remove striker eye.
7 Check joint gap around door and correct, if required.







8 Screw on striker-eye, however do not tighten.







9 Adjust hinge side of driver's door so that door panelling is flush with contour of front fender or max. 1 mm lower.
10 Check adjustment of rear door.
11 Open side window.







12 Adjust striker-eye so that door closes completely and adjust contour of panelling on driver's door by sliding striker-eye so that it is flush with rear door or max. 1 mm higher







13 Tighten striker eye (20 Nm).







14 Check contour and fit at window frame in relation to roof panelling and A-pillar and adjust, if required.

NOTE: The outer sealing lip of the door sealing frame should be flush with the edge of the roof panelling.






Door sealing frame flush with roof panelling

15 Check door for easy motion.