Door Assembly Front - I

Door Assembly Front

Panel Drawing







Pre-Repair Activities
Open door window half way before disconnecting battery.

Consumables
None.

Mechanical, Electrical and Trim, remove and install:
Door trim board (10 x clips, 3 x Pozidrive screws)
Door solid weather board (12 x T30 Torx screws)
Door window frame trim
Door mirror assembly (3 x 10 mm bolts)
Weather seal inner glass
Weather seal outer glass Door drop glass front (1 x 10 mm bolt)
Door regulator mechanism (4 x 8 mm bolts, 1 x T30 Torx screw)
Door handle, lock/inner outer assembly (5 x T40 Torx screws)
Door check strap (2 x T30 Torx screws, 2 x 10 mm nuts)
Weather seals door outer
Door glass run felt Door front exterior trim (2 x Pozidrive screws)
Wiring Loom

MET Tools
Pozidrive screwdriver
8 mm socket
10 mm socket
3/8" Drive ratchet
Torx screwdriver
T30 torx bits
T40 torx bit
Suitable trim tool
Long nose pliers

Panel Tools
13 mm socket
Torx screwdriver
T50 Torx bit
Torque wrench

01. The front door assembly is a category B bolt on panel.
Remove MET items as listed.
Complete 'Pre-Repair Activities'.







02. Split door hinges as shown (size T50 Torx bolt).

Note: Door supplied without hinges. If damaged, renew.







03. Remove upper and lower hinges from door assembly (4 x 13 mm nuts).
Fit hinges to new assembly as indicated (A/B).

Note: Bolts are pre-coated to inhibit galvanic corrosion and are reusable-only if coating is undamaged.







04. Fit and re-trim panel in reverse order.
Torque settings:
- Door to hinges (13 mm nuts) 30 Nm.

On completion of panel replacement, the following checks should be carried out:
1. Panel gaps (as indicated).
2. Hinge operation.
3. Lock alignment.
4. MET operation.