Replacing The Front Door

Preliminary work 

• Refer to DEACTIVATING THE 48 V ELECTRICAL SYSTEM .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVE FRONT DOOR TRIM PANEL .
• Refer to REMOVING THE MIRROR TRIANGLE .
• Refer to REMOVING EXTERIOR MIRROR .
• Refer to REMOVE OUTER WINDOW CHANNEL STRIP .
• Refer to REMOVE THE WINDOW CHANNEL STRIP (FRONT) ON THE FRONT DOOR .
• Refer to Release the front door window glass
• Refer to REMOVE THE MODULE BRACKET FROM THE FRONT DOOR .
• Refer to REMOVING FRONT DOOR WINDOW GLASS .
• Refer to REMOVING THE POWER ELECTRIC WINDOWS OF THE FRONT DOOR .
• Refer to REMOVE RUBBER WINDOW SEAL .
• Refer to REMOVE THE OUTSIDE DOOR HANDLE .
• Refer to REMOVING THE OUTSIDE DOOR HANDLE SUPPORT .
• Refer to REMOVING THE DOOR CHECK OF THE FRONT DOOR .

Precondition 

New part is painted.

• Pull up lock (1) in the arrow direction and unlock and disconnect plug connection (2).

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• Unclip wiring harness (1) at marked positions (arrows).

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• Loosen grommet (1).
• Feed the wiring harness out of the door.

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  NOTE: RISK OF DAMAGE 
  Mechanical effects  .
  Paint damage  .

  • Mask those working areas at risk with yellow plastic adhesive tape.
  • Remove and install heavy or bulky components with the aid of another person/other persons.

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• Secure the front door to prevent it from falling.
• Release screws (1) and remove the front door.
• Renew front door.

  Parts:  Door, front

• Secure the front door to prevent it from falling.
• Position front door at the door hinges.
• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATION
  
  

  Door hinge to door
  Countersunk screw with Torx M8	Tightening torque	19 Nm

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• Carefully close front door.
• Check the front door for bodywork contact and, if necessary, position it again.
• Guide the wiring harness into the front door.
• Mount grommet (1) and check if it fits correctly.

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• Clip in wiring harness (1) at marked positions (arrows).

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• Connect and lock connector (1) and press down lock (2).

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• Remount the seal (1).

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• Remount the clamps (1).

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• Remount the expansion nut (1).
• Remount holding clip (2).

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• Remount both seal plugs (1).
• Remount the protective cap (2).

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• Remount all seal plugs (1).

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Follow-up work 

• Refer to INSTALL THE DOOR CHECK OF THE FRONT DOOR .
• Refer to INSTALLING THE SEAL .
• Refer to INSTALLING THE OUTER DOOR HANDLE SUPPORT .
• Refer to INSTALLING THE OUTSIDE DOOR HANDLE .
• Refer to PRESERVING THE FRONT DOOR .
• Refer to INSTALL THE RUBBER WINDOW SEAL .
• Refer to INSTALLING THE POWER ELECTRIC WINDOWS OF THE FRONT DOOR .
• Refer to INSTALLING FRONT DOOR WINDOW GLASS .
• Refer to INSTALLING THE MODULE BRACKET ON THE FRONT DOOR .
• Refer to INSTALLING THE WINDOW CHANNEL STRIP (FRONT) ON THE DOOR .
• Refer to FIT VEHICLE EXTERIOR MIRROR .
• Refer to INSTALL OUTER WINDOW CHANNEL STRIP .
• Refer to INSTALLING THE MIRROR TRIANGLE .
• Refer to INSTALL FRONT DOOR TRIM PANEL .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS
• Refer to ACTIVATING THE 48 V ELECTRICAL SYSTEM .
• Refer to ADJUST FRONT DOOR .
• Refer to ADJUSTING DOOR WINDOW GLASS .