Front Door: Service and Repair

Door (76.28.04)

Removal

1. Remove battery cover, and disconnect ground cable from battery terminal.
2. Apply protective masking tape to overlap front edge of door.







3. Fully open door, withdraw harness gaiter from 'A' post, disconnect multiplugs and position them clear of 'A' post aperture.







4. Remove door.
1. Slacken and remove the two screws securing check arm to 'A' post and fully retract check arm into door.
2. Slacken, remove and discard hinge locking screws.
3. With assistance, lift door to clear hinge pins and remove door from vehicle exercising care to avoid damaging paintwork.







Installation

WARNING: FOLLOWING REPAIR OR RENEWAL OF A FRONT DOOR, IT MUST BE ENSURED THAT A SIDE AIRBAG WARNING LABEL IS AFFIXED TO THE REAR FACE OF THE DOOR.

NOTE: The hinges are set during manufacture to achieve correct door fitment. This setting should only require adjustment in the event of damage at the body or door hinge locations.

1. Using a thread chaser or grooved slave bolt, remove any residual thread locking compound from locking screw locations.
2. Ensure that multiplugs are clear of door front edge, and check arm is fully retracted, then with assistance, lift door into position and locate hinge pins.
3. Fit and fully tighten new hinge locking screws.
4. Position check arm bracket on 'A' post and fit and tighten securing screws.
5. Fully open door and apply a thin coat of grease to both sides of check arm.
6. Connect door harness multiplugs and fit and fully seat harness gaiter in 'A' post.
7. Remove masking tape from front edge of door.
8. Check that door shuts correctly.
9. Wipe any excess grease from check arm.
10. Connect ground cable to battery terminal and fit battery cover.