Body - Door Stop Mounting Repair Procedures
SECTION8
GROUP
81
NO.
807
DATE
Dec. 1995
Door stop mounting procedures 850
REFERENCE: TP 32395/2, SECTION 8 (81,84), BODY AND GLASS; 1992-
TP 31600/1, SECTION 8 (80), PAINT REPAIRWORK; 200,700
SB 83-815 12/94
Door stop mounting repair procedures
Noise when opening or closing doors can be caused by several conditions. This Service Bulletin provides information for use when investigating customer complaints of noisy doors.
If the source of noise is a loose doorstop bolt, refer to Service Bulletin 83-815; 12/94. If damage to the door stop mounting is the source, follow repair procedures listed in this bulletin.
Note:
Stiff door stops may crack the mounting and should be replaced.
Preparation for repairing door stop mounting on the cracked pillar and the inside door hinge
Remove:
- negative lead from battery
- screws (A) locking hinge joint and scrap
- screws (B) in the door stop inner mounting
- lock screw (C) in the connectors
- the front door pillar connector (D) by twisting and pulling
- connector (E) from the rear door pillar by pulling off the rubber cover (F) and pulling connector (E) out of the hole in the pillar
- disconnect connectors
- door from the car body
Note:
Be careful net to damage paintwork when the door is lifted off its hinges.
Protection against welding droplets and residue
Welding droplets on painted surfaces and residue in the car must be avoided. Fabric masking tape and protective covers should be used to seal and protect paintwork and much of the front/rear door opening.
Mask:
- Paintwork and interior with two large fireproof protective covers which are taped to the door pillars. See Figure A for front or B for rear door pillar.
- wiring, holes and connectors with fabric masking tape.
Straightening door stop mounting
The door should be at 900 to the mounting panel in the A-pillar at the front door and at 1040 in the B-pillar at the rear door.
Reinforcements of door stop mounting and pillar
General
Plug weld (A) 10-15 mm (3/8" - 5/8") from the edge of the panel whether it is cracked or not. This is used to lock the end of a crack (B).
Seam weld at (C) whether it is cracked or not and at (D) only if cracked.
Drilling
Drill plug weld holes:
- Drill a control hole with a 5 mm (13/64") dia. drill.
- Using a 8 mm (5/16") dia. drill, drill through two panels (A, B) and into but not through the third (C).
- Scrape off paint around the drill hole and doorstop mounting.
Welding
Plug weld and seam weld:
- Ensure that the battery negative lead is removed.
- MAG-weld the drill holes.
- Seam weld around the outside of the door stop mounting (A) as illustrated.
- Seam weld any cracks on the inside of the door stop mounting (B).
- Grind down the welds.
See also Service Manual Section 8 (81, 84), "Body and Glass 850 1992", "Welding and bonding" and "General".
Painting and rust treatment
Painting
Prime, fill and paint according to Service Manual section 8 (80) Paint repairwork 200, 700 which also applies to the 800 excluding plastic components.
Rust treatment
Spray:
- anti-rust protection with a curved nozzle (A) on the door stop inside the pillar through the hole for the connector.
Removal of masking
- Pull off tape and protective covers.
- Clean off residue and droplets.
Replacing components
Replace:
- The door on the inner hinge on the A- or B-pillars. Secure the hinge lug with torx 45 TXE8-screws (torque 25+/-6 Nm) P/N 6817800-3.
- Door stop and rubber boot (torque 25 Nm, 18 ft.lbf).
- Connector.
- Ensure that the doors open and that the door stops do not stick or make a noise.
- battery negative lead.
Reset radio code.
Reset clock.
Verify functions.
Operation no. Description Time allowance
83910-2 Doorstop mounting, repair solid colors 3.4 hrs
metallic colors 3.7 hrs