51 48 ... Removing and installing/replacing sound insulation/protective mat on left or right front door

Disconnect battery negative lead, refer to 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Remove airbag module on front door, refer to AIR BAG RESTRAINT SYSTEMS .

Disconnect LED with cable (1) from light housing (2).

Fig 1: Disconnecting Led With Cable From Light Housing

Pull Bowden cable (1) backwards and unclip from door handle.

Fig 2: Pulling Bowden Cable (1) Backwards And Unclipping From Door Handle

Release screws (1) and remove protective mat (2) for cable penetration.

Fig 3: Releasing Screws (1) And Removing Protective Mat (2) For Cable Penetration

CAUTION: Do not kink fiber optics cable. The bending radius of the fiber optics cable must not be less than 20 mm.

Detach central light source (1) from holder (2) towards top.

Fig 4: Detaching Central Light Source From Holder

Disconnect plug connection (1) and detach fiber optics cable (2) from central light source.

Fig 5: Disconnecting Plug Connection (1) And Detach Fiber Optics Cable (2)

Release all cable ties on speaker unit.

Disconnect plug connection (1) on speaker unit (2) at bottom.

Fig 6: Disconnecting Plug Connection (1) On Speaker Unit (2)

Disconnect plug connection (1) on wiring harness.

Fig 7: Disconnecting Plug Connection On Wiring Harness

Open clips (1) and wiring harness holder (2).

Fig 8: Opening Clips (1) And Wiring Harness Holder (2)

Expose wiring harness.

Release screws (1) and remove speaker unit (2).

Fig 9: Releasing Screws (1) And Removing Speaker Unit (2)

Release screw (1) and remove butyl compound (2) from cable penetration.

Fig 10: Removing Butyl Compound From Cable Penetration

Pull spacers (1) and (2) off stud bolts.

Installation:

Rear spacer (1) - long.

Front spacer (2) - short.

Fig 11: Identifying Front And Rear Spacer

Press rubber grommet (1) with wiring harness through sound insulation/protective mat (2).

Fig 12: Pressing Rubber Grommet (1) With Wiring Harness Through Sound Insulation/Protective Mat (2)

Unfasten screws (1) to (3).

Fig 13: Unfastening Screws

CAUTION: Carefully remove seal (1). Do not damage sound insulation/protective mat (2). Material unravels.

Installation:

Lay 6 mm dia. butylene tape for sealing all around sound insulation/protective mat.

Fig 14: Sealing All Around Sound Insulation/Protective Mat

Using special tool 00 9 317 (trim panel wedge), lever out bonding (1) of sound insulation/protective mat (2).

Carefully pull sound insulation/protective mat approx. 15 cm off stud bolts (3).

Feed wiring harness (4) and cable (5) out of sound insulation/protective mat.

Fig 15: Feeding Wiring Harness And Cable Out Of Sound Insulation/Protective Mat

Installation:

Attach sound insulation/protective mat to a stud bolt for securing airbag.

Feed in wiring harness and press rubber grommet through sound insulation/protective mat.

Seal cable penetration with butylene tape.

NOTE: Position of butylene tape (1) on inner door plate.

Fig 16: Positioning Of Butylene Tape On Inner Door Plate

NOTE: Position of butylene tape (1) on sound insulation/protective mat (2).

Fig 17: Positioning Of Butylene Tape On Sound Insulation/Protective Mat

CAUTION: When working with adhesive cleaners in enclosed rooms: Ensure room is well ventilated. The adhesive areas must be dry and free from dust and grease. After cleaning, do not touch the adhesive areas with bare hands.

If necessary, clean the specified adhesive area with adhesive cleaner.

Air drying time: 1 minute.

Lay butylene tape with a diameter of 6 mm in specified adhesive area.

Heat butylene tape (hot air blower) and firmly press down sound insulation/protective mat in specified adhesive area.

Contact pressure with hand roller: approx. 30 N/cm² . Manual contact pressure: approx. 10 N/cm²

NOTE: Firm thumb pressure has approx. 50 N/cm² .