Remove/install front door - AR72.10-P-0500K

MODEL 208

Fig 1: Identifying Front Door Remove/Install Components

	Seam sealing following repair	Includes seam sealing on driver's door	AR97.10-P-4000K
	Cavity preservation following repair work	Includes cavity preservation on driver's door	AR97.20-P-1500K
	Remove/Install
1	Remove door lining		AR72.10-P-1000K
2	Disconnect in-door speaker separation point (4) and remove in-door speaker (3)	Remove sound deadening mat from in-door speaker (4) Installation: Replace tie straps
3	Disconnect in-door speaker separation point (2) and remove in-door speaker (1)	Installation: Replace tie straps.
4	Pull door foil off of inner door panel	Installation: Replace damaged door foil, glue door foil onto inner door panel	*BR00.45-Z-1004-02A
5	Remove rocker panel molding (13) with mounting wedge		Fig 2
6	Remove door seal (7) from A-pillar
7	Remove inner base paneling (15) from A-pillar
8	Open cable duct (8) at front
9	Disconnect pneumatic line separation point (12)	Danger of breaking insert profiles A 7 mm open-end wrench can be used to separate the pneumatic line (12)
10	Disconnect side airbag separation points (9) and door control unit (10, 11)
11	Pull wiring harness through bellows (5) on A-pillar and unclip bellows (5) from front door
12	Remove door catch (6) from A-pillar.		*BA72.10-P-1003-01A
13	Unscrew bolts (16) from bottom and top hinge and slightly pull door away from A-pillar	Hold door with aid of 2nd person to prevent damaging paint. Installation: Position front door to centering bolts with hinges (17), screw on with bolts (16) and tighten
			*BA72.10-P-1001-01A
14	Remove front door and lay down on secure base	Do not damage paintwork
15	Install in the reverse order
16	Check gap dimensions at door all the way around		Fig 3
		Dimensions ↓	*BE60.00-P-1002-01A
		Gaps dimensions at hoods, doors and covers	AR60.00-P-0700-01K
		If applicable, adjust front door	AR72.10-P-0550G

TEST AND ADJUSTMENT VALUES, GAP DIMENSIONS AT HOODS, DOORS AND COVERS

Number	Designation				Model 208.3	Model 208.4
BE60.00-P-1002-01A	Gap dimension	Front door to A-pillar	Dimension "B"	mm	6.5 (±0.5)	5.0 (±1.0)
		Front door to fender	Dimension "H"	mm	4.0 (±0.5)	4.0 (±0.5)
		Front door to rear door	Dimension "I"	mm	-	-
		Front door to roof	Dimension "C"	mm	-	-
		Rear door to upper side section	Dimension "D"	mm	-	-
		Rear door to lower side section	Dimension "J"	mm	-	-
		Fender to A-pillar	Dimension "Q"	mm	-	-
		Front door to rear fender	Dimension "P"	mm	4.0 (±0.5)	4.0 (±0.5)
		Front door to rear fender	Fig., see		AR60.00-P-0700-01K	AR60.00-P-0700-01KA

FRONT DOOR

Number	Designation		Model 208.3/4
BA72.10-P-1001-01A	Bolt to door hinge	Nm	37
BA72.10-P-1003-01A	Bolt to door catch on A-pillar	Nm	25

Fig 2: Identifying Mounting Wedge (110 589 03 59 00)

Fig 3: Identifying Feeler Gage (129 589 03 21 00)

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1004-02A	Adhesives	A 001 989 30 71