Replacing The Front Door
WARNING:
Airbag unit
.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Before performing any work on the airbag, always disconnect the battery ground lead from the battery.
- Airbag unit may only be set down with the cushion (airbag itself) facing upwards.
- For additional information see: 72 00... Safety regulations on handling airbag system components/gas generators
NOTE:
Description is for left component only. Procedure on the right side is identical.
Preliminary work
- Refer to PREPARING THE SPECIAL TOOL .
- Refer to REMOVING THE OUTER FRONT WINDOW CHANNEL STRIP .
- Refer to RELEASE THE FRONT DOOR WINDOW GLASS .
- Refer to REMOVE FRONT DOOR TRIM PANEL .
- Refer to PARTIALLY REMOVING FRONT INNER WINDOW CHANNEL STRIP .
- Refer to REMOVING THE EXTERIOR MIRROR .
- Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
- Refer to REMOVING THE FRONT MODULE BRACKET .
- Refer to REMOVE FRONT DOOR WINDOW GLASS .
- Refer to PARTIALLY RELEASING REAR INNER WINDOW CHANNEL STRIP .
- Refer to REMOVING THE FRONT INNER WINDOW CHANNEL STRIP .
- Refer to REMOVE THE FRONT OUTSIDE DOOR HANDLE .
- Refer to REMOVING THE DOOR LOCK (WHEN REPLACING DOOR) .
- Refer to REMOVING THE COVER FROM THE FRONT DOOR .
- Refer to REMOVING THE DOOR CHECK OF THE FRONT DOOR .
- Unlock plug connection (1) and disconnect.
- Release the rubber grommet (1) and guide the door wiring harness (2) out of the door.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.
- Release screws (1) and carefully remove the door (2) with the help of a support person.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.
- Position the new door (2) on the door hinge with a support person.
- Tighten the screws (1).TIGHTENING TORQUES SPECIFICATION
Door hinge to door Countersunk screw with Torx M8 Tightening torque 19 Nm - Loosen screws (1).
- Feed out the crash pad (2).
- Install the crash pad (2) in the new door.
- Tighten the screws (1).TIGHTENING TORQUES SPECIFICATION
Crash pad on door Oval-head screw for thermoplastic Tightening torque 3 Nm - Remount the clamps (1).
- Remount the shaped part (1).
- Remount the nozzles (1).
- Release the screw (1) and remove the retaining clip (2).
- Position the retaining clip (2) on the new door and tighten the screw (1).TIGHTENING TORQUES SPECIFICATION
Retaining clip on door Sheet metal screw 4.8x19 Tightening torque 3 Nm - Remount the plug (1).
- Remount the clip (1).
- Remount the expansion nut (1).
- Feed the door wiring harness (2) into the door.
- Fasten the rubber grommet (1) and check for correct fit.
- Connect connectors (1) and lock.
Follow-up work
- Refer to INSTALL THE DOOR CHECK OF THE FRONT DOOR .
- Refer to INSTALLING THE SEAL .
- Refer to INSTALLING THE COVER ON THE FRONT DOOR .
- Refer to INSTALLING THE DOOR LOCK (WHEN REPLACING DOOR) .
- Refer to INSTALL THE FRONT OUTSIDE DOOR HANDLE .
- Refer to INSTALLING INNER WINDOW CHANNEL STRIP AT THE FRONT .
- Refer to PARTIALLY INSTALLING REAR INNER WINDOW CHANNEL STRIP .
- Refer to INSTALLING FRONT DOOR WINDOW GLASS .
- Refer to INSTALLING THE FRONT MODULE BRACKET .
- Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
- Refer to INSTALLING THE OUTSIDE REARVIEW MIRROR .
- Refer to PARTIALLY INSTALLING INNER WINDOW CHANNEL STRIP AT THE FRONT .
- Refer to ADJUST DOOR .
- Refer to ADJUSTING DOOR WINDOW GLASS .
- Refer to INSTALLING THE OUTER FRONT WINDOW CHANNEL STRIP .
- Refer to INSTALL FRONT DOOR TRIM PANEL .