Contents: Door ⬇ Electric window lift motor ⬇ Door glass ⬇ Exterior rear door trim panel for…⬇ Assembly holder in the rear door ⬇ Assembly holder in the front door ⬇ Seals ⬇ Front door unlocking and locking…⬇ Rear Door Unlocking and Locking…⬇
Note: The removal and installation of the outside mirror is described in Section 11; a description of the removal of parts installed on the inside of the door is given in Parts B.
Note: After working with the locking elements, make sure that they function properly before closing the door.
Door
Note: The following description is for the front door; on the rear door the actions are similar, and only explanatory illustrations are given for it.
1. Door fastening details and their main parts are shown in the accompanying illustrations.
10.1a Fastening parts and main elements of the front door
1 Door
2 External handle
3 Support
4 Lock cylinder
5, 6 Plug
7 Bolt, 20 Nm
8 Castle striker
9 Bolt, 22 Nm
10 Castle
11 Cable
12 Inner release handle
13 Bolt, 25 Nm
14 Bottom loop
15 Bolt, 40 Nm
16 Door travel limiter
17 Bolt, 9 Nm
18 Bolt, 30 Nm
19 Upper loop
10.1b Fastening parts and main components of the rear door
1 Door
2 External handle
3 Support
4, 5 Plug
6 Bolt, 20 Nm
7 Castle striker
8 Bolt, 22 Nm
9 Inner cable
11 Inner release handle
12 Bolt, 25 Nm
13 Bottom loop
14 Bolt, 40 Nm
15 Door travel limiter
16 Bolt, 9 Nm
17 Bolt, 30 Nm
18 Upper door hinge
2. On models with side airbags, disconnect the negative battery cable with the ignition on.
3. Turn off the ignition. Disconnect the corrugated pipe from the A-pillar (6 on the accompanying illustration), disconnect the connectors (4), loosen the nuts (2) of the hinges (1), unscrew the bolt (5) of the limiter (3) and remove the door upwards.
10.3 Removing the front door
4. Installation is carried out in the reverse order. Remove the bracket (2 on the accompanying illustration) corrugations from the A-pillar, insert it into the corrugation (1) and install the bracket with the corrugation into the A-pillar.
10.4 Installation of corrugation
5. To properly adjust the door, loosen the fasteners of its hinges (to the counter and to the door) and set the door. Other adjustment methods (for example, aligning doors at the top) not effective (the door will fall again if pressed again). The doors are adjusted correctly if there is an even gap between them and the frame around the entire perimeter (see Specifications).
Electric window lift motor
6. Turn off the ignition and remove the door trim (see Part B).
7. Disconnect the connector (2 on the accompanying illustration), unscrew the bolts (1) and remove the electric motor (2) of the window lifter from the assembly holder.
10.7 Fastening the electric window motor
8. When installing, tighten the bolts to 2.9 Nm.
Door glass
9. Remove the door trim (see Part B). On the rear door, remove the assembly holder.
10. Roll down the window (1 on the accompanying illustrations) enough to allow access to the expansion pin (3) and expansion sleeve (4) through the opening in the door. Secure the glass to the frame using adhesive tape so that it does not fall after the expansion sleeves are removed.
10.10a Removing the front glass
10.10b Removing the rear window
11. Screw an M5 bolt approximately 70 mm long into the expansion pin and separate it from the expansion pin. Screw an M8 bolt approximately 80 mm long into the expansion sleeve and remove the sleeve from the glass and its guide. When screwing in the bolt, do not apply excessive force so that the sleeve does not fall into the door.
12. Lower the glass, remove its inner seal and remove the glass from the door.
13. Installation is carried out in the reverse order. Install the bushing and pin to a depth (and in illustrations 10.10a-b) 0.75±0.2 mm.
Exterior rear door trim panel for station wagon models
14. Separate the door seal in the area of the arrows and unscrew the bolts (2 on the accompanying illustration). Then lift the outer trim panel (1) slightly and press the seal backwards (dotted arrows).
10.14 Removing the rear door outer trim panel
15. Installation is carried out in the reverse order. Tighten the bolts with a force of 2 Nm.
Assembly holder in the rear door
Note: The assembly holder is removed together with the window lifter.
16. Turn off the ignition and remove the door trim (see Part B).
17. Disconnect the single lock control unit connector and remove the window lifter electric motor (see subsection above).
18. Remove the expansion pin (1 on the accompanying illustration) and fix the glass to the frame with adhesive tape. Unscrew the bolts (3) and remove the assembly holder (2) together with the window lifter.
10.18 Fastening the assembly holder in the rear door
19. Installation is carried out in the reverse order. Tighten the assembly holder bolts with a force of 10 Nm.
Assembly holder in the front door
Note: The assembly holder is removed together with the window lifter.
20. Turn off the ignition and remove the door trim (see Part B).
21. Disconnect the single lock control unit connector and remove the window lifter electric motor (see subsection above).
22. Remove the expansion pins (1 on the accompanying illustration) and fix the glass on the frame with adhesive tape. Unscrew the bolts (4), remove the self-adhesive plugs (3), unscrew the bolts (2) of the guide channels and remove the assembly holder (2) together with the window lifter.
10.22 Fastening the assembly holder in the front door
23. Installation is carried out in the reverse order. Tighten the bolts of the assembly holder and guide channels with a force of 10 Nm.
Seals
24. The location of the seals is shown in the accompanying illustrations.
10.24a Front door seals
1 Front door
2 Bolt, 2.5 Nm
3 Outer trim of B-pillar
4 Spring nut
5 Overlay strip
6 Glass guide
7/8 Sealing of outer/inner channel
9 Plug
10 Inner seal, installed starting from the top rounding
11 Outer seal joint
12 Damper
13 Protective film
14 Outer seal
A Distance from the bottom of the opening to the seal joint 10, 310 mm
10.24a Rear door seals
1 Glass
2 Spring nut
3 Outer trim of B-pillar
4 Bolt, 2.5 Nm
5 Bolt, 3 Nm
6 Gasket
7 Triangular window
8/9 Upper/lower band
10 Door
11 Inner seal, installed starting from the top rounding
12 Outer seal joint
13 Outer seal
14 Bolt, 4 Nm
15 Sealing the inner channel
Front door unlocking and locking parts
25. The fastening of the driver's door unlocking and locking parts is shown in the accompanying illustration. To remove the holder (1), remove the assembly holder (see the relevant subsection above), escutcheon (5), the lock cylinder and the outer handle. Then unhook the cable and unscrew the bolt (7).
10.25 Fastening of driver's door unlocking and locking parts
1 Holder
2 Front door
3 Support
4 Lock cylinder
5 Overlay; it only comes off on the driver's door; on the right front door it is removed in the same way as on the rear doors
6 External handle
7 Bolt, 1.7 Nm
8, 9 Plug
10 Bolt, 20 Nm
11 Inner cable
12 Castle
13 External cable
14 Bolt, 2.2 Nm
26. To remove the lock cylinder, unhook the cover plate (5 in illustration 10.25), insert the key into the lock (1 on the accompanying illustration), loosen bolt (3) about three turns, push it to loosen the lock, and then completely remove this bolt. Loosen bolt (2) enough so that the lock cylinder can be pressed out of the door (turn the key in the lock about 90°).
10.26 Lock cylinder mounting bolts
27. To remove the outer handle, remove the lock cylinder (see paragraph 26) and slide the handle towards the lock hole until the tab on the handle comes out of the holder. Tilt the handle and remove it from the door.
28. To remove the lock, remove the interior door trim (see Part B), remove the bolts (9 in illustration 10.25), disconnect the speaker connector, drill out its rivets and remove the speaker. Then separate the inner and outer cables and remove the lock.
Rear Door Unlocking and Locking Details
29. The fastening of the driver's door unlocking and locking parts is shown in the accompanying illustration. Further references in this subsection refer to this illustration.
10.29 Fastening of rear door unlocking and locking parts
1 Holder
2 Back door
3 Support
4 Overlay
5 External handle
6 Bolt, 1 Nm
7 Plug
8 Bolt, 20 Nm
9 Inner cable
10 Castle
11 External cable
12 Retainer
30. To remove the holder (1), remove the assembly holder (see the relevant subsection above), cover (4) and the outer handle. Then unhook the cable and unscrew the bolt (6).
31. To remove the cover (4), remove the plug (7), insert a welding electrode at least 110 mm long with a 4 mm bent end into the resulting hole until it stops, and press the lock (12) by 5 mm.
32. To remove the outside handle, remove the cover (4) and slide the handle towards the lock hole until the tab on the handle comes out of the holder. Tilt the handle and remove it from the door.
33. To remove the lock, remove the interior door trim (see Part B), unscrew the bolts (8) and separate the inner and outer cables.