Front Door Panel: Service and Repair

Panel front side door, replacing

As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparations




Remove the battery lead. See Battery, disconnecting Battery Disconnecting.

Removing the panel from the front door




Remove the handle using a weatherstrip tool. Start from one side.

Remove:
- the cover at the base of the door mirror
- the 2 screws.
Pull off the panel.

Remove:
- the connectors
- the cable. See Cable, internal handle, front side door, replacing Cable, Internal Handle, Front Side Door, Replacing.





Transferring components for extra armrest (if installed)




Apply marking paint to the spots indicated in the illustration.




Guide the armrest into place and follow the door panel radius (see marking on illustration) without pressing the armrest against the door panel.
Once the armrest is in the correct position, press the armrest against the door panel to mark the holes.
Remove the armrest from the door panel.




Drill the marked spots using a 10 mm drill bit.




Drill the holes for the armrest guides. Use a 10 mm drill bit and drill at a 45 degree angle from the door panel.




Then continue working the holes with a file. Hole width should be 20 mm.
Test mount the armrest on the door panel. If necessary, use the file to make adjustments so that the armrest fits well against the door panel.
Install the armrest on the door panel with 4 flat washers (P/N 960 138) and 4 screws (P/N 979 187).

Installing the panel on the front door

Note! For tightening torques, see [1][2]Body and Frame





Install:
- the cable. See Cable, internal handle, front side door, replacing Cable, Internal Handle, Front Side Door, Replacing
- the connectors.
Press the panel into place.

Note! Align the panel so that the clips are in the correct position. The panel clips can be separated.

Install:
- the 2 M6 screws. Tighten
- the cover at the base of the door mirror
- the handle.




Press the front edge of the handle into position.




Hold the handle in position and press in both sides.