Assembling door

Peel off the backing and stick the insulation into the door below the side-impact bar.

Fig 1: Sticking Insulation Into Door Below Side-Impact Bar

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Position the angle piece with the 12 x 8 x 7 centering sleeve on the door and fasten with the T 45 M8 x 33 Torx screw.

1. Tightening torque: 23 Nm(17 ftlb.) 

Fig 2: Fitting Angle Piece

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1. Insert wiring harness into the door in the -direction of the arrow-.
2. Clip in the electrical wiring along the inner door panel.

Fig 3: Fitting Wiring Harness

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Fig 4: Fitting Lid

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Press in the 24 x 40 lid -A- and the 20 x 28 lid -B-

Position the door channel seal on the inside -arrow- in the bead of the door channel and press it on.

Fig 5: Fitting Door Channel Seal On Inside

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1. Push on the B 3.5 sheetmetal nut.
2. Position the window guide rail and fasten it with the B3.5 x 9.5 sheetmetal screw.

   Tightening torque: 1.4 Nm (1.0 ftlb.) 

Fig 6: Fitting Window Guide Rail

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Fig 7: Fitting Door Seal On Outside

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Position door seal on the outside at the top edge of the door and push it on.

1. Clip in the seal along the door contour.
2. Fasten the door seal on the inner door panel with the clip -A-.

1. Position the seal.
2. Insert door brake from the inside and fasten it with the collar nuts.

   Tightening torque: 10 Nm (7.5 ftlb.) 

3. Screw Torx screw M8-A-onto the A-pillar.

   Tightening torque: 23 Nm (17 ftlb.) 

Fig 8: Fitting Door Brake

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1. Insert power window unit into the door opening from below.
2. Fasten the power window unit with the M6 collar nuts.

   Tightening torque: 10 Nm (7.5 ftlb.) 

   See: Additional adjustment instructions for the power window.

3. Plug in the electrical plug connection.

Fig 9: Fitting Power Window Unit

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1. Insert door window into the door channel and position it in the front and rear clamping pieces of the power window unit.
   NOTE:

   • The bottom edge of the window must rest on the screw during adjustment!
   • Observe additional instructions for adjusting the door window!
2. Tighten the T 30 Torx screw.

   Tightening torque: 8.5 +/- 1.5 Nm (6.5 +/- 1.0 ftlb.) 

Fig 10: Fitting Door Window

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1. Insert door lock with actuating motor unit into the door and fasten with the micro-encapsulated T40 M8 x 14 Torx screw.

   Tightening torque: 20 + 2 Nm (15.0 + 1.5 ftlb.) 

2. Plug in the electrical plug connection.

Fig 11: Fitting Door Lock

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1. Clip in the electrical lead -B- on the base.
2. Insert door handle and position the bottom part of the door handle on the door handle from inside. Tighten with the collar nuts M 6

   Tightening torque: 10 Nm (7.5 ftlb.) 

3. Connect electrical plug connection -A-.

Fig 12: Fitting Connection Piece On Outside Door Handle

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1. Insert the connection piece into the actuating shaft -arrow A-without play.
2. Push out the sliding piece -arrow B- until it can be heard to engage.
3. Actuate the handle -arrow C- to ensure that the handle and door lock function without play.

Fig 13: Disconnecting Connection Piece From Outside Door Handle

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1. Insert bowden cable into the actuating lever -arrow D- and rotate by 90° -arrow C-.
2. Clip bowden cable into the door lock -arrow B-.
3. Engage support frame -arrow A- on the door lock.

Fig 14: Fitting Bowden Cable To Door Lock

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Position the mount in the door and fasten it with the M6 x 16 hexagon-head bolt.

Tightening torque: 10 Nm (7.5 ftlb.) 

Fig 15: Fitting Mount

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