Doors

Doors

Replacing lock cylinder

Handle




Remove 2 screws (A).

Exactly how the handle is removed is not yet clear.

Lock cylinder




Lift the lock facing.
Push out lock cylinder from the back. The key is not required to do this.

Caution! When installing it the key should not be in the lock. If the key is in the lock the lock cylinder may be installed in the wrong position.

Door panel

Door panel





Remove:
- 1 screw in handle.
- panel trim around door handle.
- door mirror panel.
Unclip 7 clips at the bottom of the door.
Pull off panel.

Door panel




Press the window lift mechanism control panel up by hand from the inside.
Disconnect connectors.

Replacing driver's side panel
The spare panel does not have a cut-out for the power mirror control. Only a stamped section on the reverse of the panel. Carry out the following:
- Cut along the perforation in the card on the reverse of the panel with a small knife.

Caution! Do not cut through the fabric.

- Press out the piece of card from the front
- Cut away the fabric on the front.

Equipment on and in the door

Door mirror
Remove door mirror according to Door mirror Removal and Replacement.

Power window mechanism cassette





Note! The window must be up to lift out the cassette. If the window is locked in the lower position due to a defective motor or cable, the cable must be cut by the motor. To replace motor and cable Replacing lift mechanism motor and cable for side window . (Service Bulletin Group (3(35-38), Lighting, instrumentation and other electrical equipment, C70)

Remove lock nuts on both adjustment screws.

Note! Note the number of turns the adjustment screws are screwed in. This will help when adjusting the cassette later, see Adjustment.

Screw in both adjustment screws as far as they will go.

Remove:
- connector and loudspeaker.
- 6 screws at the top of the door holding the cassette to the door.
- 2 door handle screws.
- connector and 3 lift mechanism motor nuts.
- 2 SIPS-block screws at the bottom of the door.
Lift out the SIPS-blocks.
Lift out power window mechanism cassette.

Caution! Take care not to damage the door when lifting out the cassette.

Installing
Before tightening the 6 screws at the top of the power window mechanism cassette, the door must be closed so that it is properly aligned.

Window in power window mechanism cassette

Note! Secure the window as follows to get the adjustment right.

The height of the carriage should be adjusted according to Replacing lift mechanism motor and cable for side window . (Service Bulletin Group (3(35-38), Lighting, instrumentation and other electrical equipment, C70)
Both carriages should be in contact with the guide rails.
Locate the lower spacers in their grooves.
Install the window and the upper spacer.
Finger tighten screws.
Press the window down to the stop lug.
Tighten screws.
Replacing lift mechanism motor and cables Replacing lift mechanism motor and cable for side window . (Service Bulletin Group (3(35-38), Lighting, instrumentation and other electrical equipment, C70)

Soundproofing panel




The soundproofing panels in the doors must be intact and properly bonded to the door for the sound system to maintain its high sound quality.

Caution! If a soundproofing panel is damaged, it must be replaced.

Lock unit

Lock unit screws




Remove power window mechanism cassette according to Equipment on and in the door.
Slacken off lock unit screws (B)

Lock unit




Remove 2 screws.
Disconnect 2 connectors.
Disconnect lock cable from lock as illustrated.

Adjustment

Adjusting the window vertically
When the door is shut two things happen to the window:
- The window is pressed against the weatherstrip.
- Because of its design the window is pressed upwards.

It is important that the window is correctly adjusted so that it does not come outside the trim strip when the door is shut.




Adjust the upper window position when the cassette is in position in the door. Its height can only be adjusted with a adjustment screw on one carriage.

Original position:
- The height adjustment screw should be in the same position as it was when the cables were removed.
- The carriage without an adjustment screw should not be tightened to the cable.

Connect motor connector and switch on the ignition.
Run the window up so that the adjustment screw is just in contact with the stop at top of the door.
Adjust the other carriage so that the window is level with the molding on the door mirror and just under the trim strip. (The carriage can only be moved up and down approximately 10 mm).
Mark the cable at the bottom of the guide rail with a felt pen.
Run the window down a little.
Tighten the screw that locks the guide rail to the wire by the mark.
Adjust the adjustment screw if necessary.

Adjusting window from side to side




The window can be adjusted from side to side using two screws at the bottom of the cassette.

Original position:
Screw out the adjustment screws (as many turns as you noted when the window cassette was removed) (approximately 5 turns), see Power window mechanism cassette

Checking the seal




Check that the window makes a seal with the weatherstrip around the door opening by folding a piece of 70 g paper in two and pulling it out. It should be hard to pull the paper out but not so hard that the paper rips.
Check that the window is in contact with the weatherstrip all the way around the window with the paper.
Repeat the vertical and side to side adjustment until the window is correctly positioned against the weatherstrip.
When the window is correctly positioned lock the adjustment screws at the bottom of the cassette.

Adjusting doors




- The doors should be easy to open/close
- The edge of the door should be flush with the outside of the car. The rear edge of the door should be 0 - 1.5 mm from the bodywork.
Door length can be adjusted by installing or removing shims on the upper and lower hinges.
0.5 and 0.3 mm shims are available as replacement parts.

Adjusting striker plate




The door must not rest on the striker plate. The striker plate must not press the door upwards.
There are rectangular holes in the striker plate.
Slacken off striker plate screws just enough to allow the striker plate to be moved stiffly.
Hold out the handle while closing and opening the door. Repeat until the striker plate is correctly adjusted.
Then tighten striker plate screws.
Check lock function by opening and closing the door.

Adjusting outside handle travel




Insert the key into the lock and turn is so that the lock rod is out of the way of the screwdriver.
Adjust using a cross-head screwdriver.