Assembling door

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2004 Porsche Boxster, 2003 Porsche Boxster, 2002 Porsche Boxster, 2001 Porsche Boxster, and 2000 Porsche Boxster. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Danger of injury if side airbag units in the door are triggered while ignition key is not removed!

Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed!
The ground strap of the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair!

NOTE: Follow the special instructions on installation and adjustment for assembly of the door!

Stick in the insulation
NOTE: In order to achieve better adhesion, heat the insulation using a hot-air gun!

Fig 1: Sticking In Insulation
Courtesy of PORSCHE OF NORTH AMERICA, INC.

Peel off the backing and stick the insulation into the door below the side-impact bar.
Fit angle piece
Position the angle piece with the 12x8x7 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
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit wiring harness
1. Insert wiring harness into the door in the -direction of the arrow- . See Fig 3 .
2. Clip in the electrical wiring along the inner door panel.
  
  Fig 3: Fitting Wiring Harness In Door
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit lid
Press in the 24 x 40 lid -A- and the 20 x 28 lid -B- . See Fig 4 .

Fig 4: Fitting Lid
Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit door channel seal on inside
1. Position the door channel seal on the inside -arrow- in the bead of the door channel and press it on. See Fig 5 .
  
  Fig 5: Fitting Door Channel Seal On Inside
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit window guide rail
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.
  1. Tightening torque: 1.4 Nm (1 ftlb.)
    
    Fig 6: Fitting Window Guide Rail
    Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit door seal on outside
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- . See Fig 7 .
Fitting door brake
1. Position the seal,
2. Insert door brake from the inside and fasten it with the collar nuts.
  1. Tightening torque: 10 Nm (7.5 ftlb.)
3. Screw Torx screw M8 -A- onto the A-pillar. See Fig 8 .
  1. Tightening torque: 23 Nm (17 ftlb.)
    
    Fig 8: Fitting Door Brake
    Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit power window unit
1. Insert power window unit into the door opening from below.
2. Fasten the power window unit with the M6 collar nuts.
  1. Tightening torque: 10 Nm (7.5 ftlb.)
  2. See: Additional adjustment instructions for the power window.
3. Plug in the electrical plug connection.
  
  Fig 9: Fitting Power Window Unit
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit door window
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.
  1. Tightening torque: 8.5 +1.5 Nm (6.0 +/- 1.0 ftlb.)
Fit door lock
NOTE:
- The actuating lever must be backed in basic position before installation!
- Observe additional instructions for adjusting the door lock!
1. Insert door lock with actuating motor unit into the door and fasten with the micro-encapsulated T40 M8 x 14 Torx screw.
  1. Tightening torque: 20 +2 Nm (15.0 + 1.5 ftlb.)
2. Plug in the electrical plug connection.
  
  Fig 11: Fitting Door Lock
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit connection piece
1. Clip in the electrical lead -B- on the base. See Fig 12 .
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.
  1. Tightening torque: 10 Nm (7.5 ftlb.)
3. Connect electrical plug connection -A- . See Fig 12 .
  
  Fig 12: Fitting Exterior Door Handle
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Disconnect connection piece
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. See Fig 13 .
3. Actuate the handle -arrow C- to ensure that the handle and door lock function without play. See Fig 13 .
  
  Fig 13: Inserting Connection Piece Into The Actuating Shaft Of Exterior Door Handle
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit bowden cable
1. Insert bowden cable into the actuating lever -arrow D- and rotate by 90° -arrow C- . See Fig 14 .
2. Clip bowden cable into the door lock -arrow B- . See Fig 14 .
3. Engage support frame -arrow A- on the door lock. See Fig 14 .
  
  Fig 14: Fitting Bowden Cable Into The Door Lock
  Courtesy of PORSCHE OF NORTH AMERICA, INC.
Fit mount
1. Position the mount in the door and fasten it with the M6 x 16 hexagon-head bolt.
2. Tightening torque: 10 Nm (7.5 ftlb.)
  
  Fig 15: Fitting Mount
  Courtesy of PORSCHE OF NORTH AMERICA, INC.