Assembling Front Door Sub-Frame: Notes

WARNING: This page is about a different car, the 2010 Porsche Cayenne, 2009 Porsche Cayenne, and 2008 Porsche Cayenne. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Front Door Sub-Frame

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Affixing foam seal to the rear of the support plate
1. 1.1. Clean marked area -1- on the support plate -2- . The area must be completely free of any greasy residues.
2. 1.2. Stick self-adhesive foam seal in the marked area -1- . The foam seal must not be deformed or stretched in the process.
  
  Fig 2: Identifying Front Door Sub-Frame
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Securing the support plate on the door frame
1. 2.1. Place the support plate -2- on the door frame -3- and align it roughly.
  
  Fig 3: Identifying Door Frame Support Plate Mounting Pin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 4: Identifying Door Frame Support Plate Mounting Pin
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 2.2. Fix the support plate to the door frame using four rivets -4- . Rivet the rivets in the sequence -A, B, C, D- .
  Hand riveting tool for pop rivets Nr.124-1 Nozzle tips for hand rivet extractors Nr.124-2
  
  Fig 5: Identifying Door Frame Support Plate Fixing Rivets (1 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 6: Identifying Door Frame Support Plate Fixing Rivets (2 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 2.3. Rivet the joint areas between the support plate -2- and door frame -3- at the side -5- .
  Hand riveting tool for pop rivets Nr.124-1 Nozzle tips for hand rivet extractors Nr.124-2
  
  Fig 7: Identifying Door Frame Support Two Plate Fixing Rivets (1 Of 3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 8: Identifying Door Frame Support Two Plate Fixing Rivets (2 Of 3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 9: Identifying Door Frame Support Two Plate Fixing Rivets (3 Of 3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installing front cover cap
1. 3.1. Attach the front cover cap -6- to the door unit carrier using the locking tabs and clip it in.
  
  Fig 10: Installing Front Cover Cap
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 11: Identifying Front Cover Cap
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installing rear cover cap
1. 4.1. Attach rear cover -7- to the door sub-frame using the locking tab and swivel to end position (-Arrows- ).
  
  Fig 12: Installing Rear Cover Cap
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 4.2. Rivet the rear cover -7- to the door sub-frame -8- .
  
  Fig 13: Identifying Door Sub-Frame Rear Cover Rivet (1 Of 3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 14: Identifying Door Sub-Frame Rear Cover Rivet (2 Of 3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 15: Identifying Door Sub-Frame Rear Cover Rivet (3 Of 3)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Inserting expanding nuts
1. 5.1. Press in the expanding nuts -9- on the lower edge of the door sub-frame.
  
  Fig 16: Identifying Lower Edge Of Door Sub-Frame Expanding Nuts (1 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 17: Identifying Lower Edge Of Door Sub-Frame Expanding Nuts (2 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installing inner window shaft moulding
1. 6.1. Position the inner window shaft moulding -10- in the front area (-arrow A- ).
  
  Fig 18: Positioning Inner Window Shaft Moulding In Front Area
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 6.2. Centre the inner window shaft moulding -10- and press it evenly on to the door sub-frame over the entire length (-arrow B- ).
  
  Fig 19: Pressing Inner Window Shaft Moulding
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installing the window seal
1. 7.1. Lay out window seal -11- as shown and fit to the window frame in the top corner.
  
  Fig 20: Identifying Window Seal
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 7.2. Insert the plastic cover -12- (-arrow C- ) and push it against the corner area of the window seal (-arrow D- ).
  
  Fig 21: Inserting Plastic Cover
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 7.3. Attach the window seal to the door frame along the B-pillar, roof rail, and A-pillar.
Turning the component on the assembly table
Installing the door seal
Information

As a general rule, a new door seal must be fitted when assembling the door unit carrier.
1. 9.1. Fit door seal -13- to the door sub-frame in the front area.
2. 9.2. The connection point -14- of the door seal must be in the marked area (-arrow E- ).
3. 9.3. Lay door seal -13- all round the door sub-frame and fit it. Take care not to deform or stretch the seal, especially in rounded areas.
4. 9.4. Check that door seal -13- is seated properly on door sub-frame.
  
  Fig 22: Locating Door Sub-Frame Seal (1 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 23: Locating Door Sub-Frame Seal (2 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Inserting the grommet
1. 10.1. Push the grommet -15- into the door frame until it clicks into place.
  
  Fig 24: Identifying Door Frame Grommet
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installing wiring harness
1. 11.1. Lay wiring harness -16- on door unit carrier as shown.
  
  Fig 25: Locating Door Wiring Harness (1 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 11.2. Clip wiring harness -16- into the door sub-frame at the marked positions (-arrows A to F- ).
  
  Fig 26: Locating Door Wiring Harness (2 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 11.3. Guide front part (transition to A-pillar) of wiring harness through the door sub-frame (-arrow G- ) and pull it out to the front (-arrow H- ). Make sure that the rubber sleeve is not twisted when fitted.
  
  Fig 27: Pulling Out Door Wiring Harness (1 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 28: Pulling Out Door Wiring Harness (1 Of 2)
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Completing the door lock
1. 12.1. Engage bowden cable -18- on door lock actuating mechanism and swivel by 90° (-arrow I- ).
  
  Fig 29: Engaging Bowden Cable On Door Lock Actuating Mechanism
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 12.2. Clip in fastening of bowden cable -19- on door lock -17- (-arrow J- ).
  
  Fig 30: Clipping In Fastening Of Bowden Cable
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 12.3. Fit lock retaining bracket -20- (-arrow K- ).
  
  Fig 31: Fitting Lock Retaining Bracket
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 12.4. Rivet the lock retaining bracket -20- to the door lock -17- from the rear (-21- ).
  
  Fig 32: Installing Lock Retaining Bracket Rivet
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Clipping in cable element
1. 13.1. Clip cable element -22- on to lever mechanism -23- (-arrow L- ).
  
  Fig 33: Clipping In Cable Element
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 34: Clipping In Cable Element
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 35: Identifying Cable Element Position In Front Door
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installing door lock
1. 14.1. Lay wiring harness -16- as shown.
2. 14.2. Guide bowden cable -18- through the door sub-frame and insert door lock -17- (-arrow A- ).
  
  Fig 36: Installing Door Lock
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Riveting the door lock
1. 15.1. Insert electric plug connections (-arrows B, C- ) until they lock with an audible click.
  
  Fig 37: Inserting Electric Plug Connections
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 15.2. Insert the rivets -25- (-arrows D- ) and rivet the door lock to the door sub-frame.
  
  Fig 38: Inserting Rivets To Door Lock System
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 15.3. Position the cover -40- and clip it into place (-arrow F- ).
  
  Fig 39: Positioning Cover And Clip
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install the power window mechanism.
1. 16.1. Place the power window mechanism on the door frame as shown. Make sure the cables are in the correct position (-arrow E- ).
  
  Fig 40: Locating Power Window Mechanism
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 16.2. Clip power window gear -26- in the door sub-frame.
  
  Fig 41: Identifying Power Window Gear Door Sub-Frame Clip
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
3. 16.3. Fix the guide rails -27- with 2 rivets each -28- and rivet to the door frame.
  
  Fig 42: Identifying Guide Rails Rivets
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 16.4. Clip retaining clip -29- in the door sub-frame and engage the cable.
  
  Fig 43: Identifying Door Sub-Frame Cable Retaining Clip
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
5. 16.5. Apply lubricant (grease) to the guide rails and move the sliding pads -30- manually.
  
  Fig 44: Identifying Lubricant Applying Area On Guide Rails
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
  
  Fig 45: Identifying Lubricant Applying Area On Guide Rails
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Stick on insulating material -33- .

Fig 46: Identifying Insulating Material Stick
Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Install door window glass. → Installing Front Door Window
Installing the power window drive
1. 19.1. Connect window regulator motor -34- and control unit -35- and clip into place.
  
  Fig 47: Connecting Window Regulator Motor And Control Unit
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
2. 19.2. Position the power window drive on the power window gear.
3. 19.3. Screw in fastening screws -36- and tighten to the specified tightening torque.
  → Tightening torque: 3.0 Nm+/-0.3 Nm
  
  Fig 48: Identifying Power Window Drive Mounting Screw
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
4. 19.4. Connect electric push-on connector -37- .
  
  Fig 49: Identifying Electric Push-On Connector Mounting Screw
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.
Installing the door sub-frame
1. 20.1. → INSTALLING FRONT DOOR SUB-FRAME
Installing the loudspeaker
1. 21.1. Position the loudspeaker -38- and rivet to the door sub-frame at the marked positions (-Arrows- ).
2. 21.2. Connect electric plug connection -39- (-arrow D- ).
  
  Fig 50: Locating Electric Plug Connection
  Courtesy of PORSCHE CARS NORTH AMERICA, INC.