Door Stop Brackets - Repairing
87saab01FILE IN S.I. Man VOL. I
SEC. B-8 PG. 20
Service Information
SUBJECT: REPAIRING DOOR STOP BRACKETS ISSUE: 07/87-984
APPLICATION: 9000 MODELS
FIGURE 1 - DOOR STOP BRACKET:
Use of excessive force when opening the door may cause a door stop bracket to pull away from the A or B-pillar. Due to their location replacement brackets are not available and a damaged bracket must be repaired. See the procedure given on the following pages for making this repair.
Note: 9000 models from VIN Serial No. H1021806 are reinforced at the door stop bracket.
Preliminary Action
Inspect the damaged door stop.
Depending on the location of the door stop it will be necessary to make a heat shield before any welding takes place.
FIGURE 2 - A-PILLAR HEAT SHIELD:
Making an A-pillar Heat Shield
Obtain a piece of 20 gauge sheet metal.
From this sheet metal, cut out a shield that matches the drawing shown to the right (see Figure 2).
This shield will protect the wiring harness located within the A-pillar.
FIGURE 3 - B-PILLAR HEAT SHIELD:
Making a B-pillar Heat Shield
Obtain a piece of 20 gauge sheet metal.
From this sheet metal, cut out a shield that matches the drawing shown to the right (see Figure 3).
This shield will protect the seat belt and wiring harness that is inside the Bpillar.
Repairing A-pillar Bracket
Note: Before starting any electric welding, disconnect both battery leads, cover the terminal poles and unplug all ECUs, i.e. EZK, LH, APC & ACC.
1. Remove the door sill scuff plate and ease the door seal away from the Apillar.
2. Peel back the rubber from the roll pin for the door stop to make the Apillar accessible for drilling.
FIGURE 4 - LOCATIONS OF BUTTON-HOLE WELDS:
3. Mark out and drill four 8 mm pilot holes as shown in Figure 4. The sheet metal is double thickness at this point.
If the bracket has broken completely off, position the bracket correctly in relation to the A-pillar and mark the location with a scribe for subsequent welding.
FIGURE 5 - RELEASING THE HINGE HALVES:
4. Remove the rubber grommet and unplug the wiring harness connectors in the A-pillar.
5. Tap out the door stop roll pin and hold the bracket in position with a drift. If the bracket has broken loose do not let if fall inside the body.
6. Open the door wide to release the halves of the hinge (see Figure 5) and carefully lift off the door.
FIGURE 6 - LOCATING THE HEAT SHIELD WITH A WEDGE:
7. Insert the heat shield through the opening in the A-pillar for the wiring harness. Push the harness as far as possible away from the area to be welded and locate the heat shield into position using a wooden wedge or similar item (see Figure 6).
FIGURE 7 - BUTTON-HOLE WELDING THE DOOR STOP BRACKET:
8. Using a drift to hold the door stop bracket in position, button-hole weld the four holes (see Figure 7). Have an air gun available so that it can be used to cool the welds rapidly.
9. Remove the heat shield and inspect the wiring harness to ensure that none of the wiring has been damaged.
10. Grind the welds and apply primer followed by touch-up paint as necessary.
11. Rehang the door and reconnect the wiring harness.
12. Refit the rubber cover and fit a new roll pin in the door stop.
13. Refit the door seal and scuff plate.
14. Reconnect all ECU's and the battery. Check all electrical functions in the door.
Repairing B-pillar Bracket
Note: Before starting any electric welding, disconnect both battery leads, cover the terminal poles and unplug all ECU's, i.e. EZK, LH, APC & ACC.
1. Remove the front and rear scuff plates, ease the front and rear door seal away from the B-pillar, remove the B-pillar trim and the plastic cover from the seat belt mounting point.
2. Unscrew the door microswitch.
FIGURE 1 - LOCATING THE HEAT SHIELD WITH A WEDGE.:
3. Secure the heat shield in position in the B-pillar to protect the wiring harness and seat belt (see Figure 1).
4. Remove the seat belt reel from the B-pillar and leave it inside the car. Unplug the electrical connector from the reel.
5. Peel back the rubber cover from the roll pin for the door stop to make the B-pillar accessible for drilling.
FIGURE 2 - LOCATIONS OF BUTTON-HOLE WELDS.:
6. Mark out and drill four 8 mm pilot holes as shown in Figure 2. If the bracket has broken completely off, position the bracket correctly in relation to the B-pillar and mark the location with a scribe for subsequent welding.
FIGURE 3 - BUTTON-HOLE WELDING THE DOOR STOP BRACKET.:
7. Tap out the door stop roll pin and hold the bracket in position by means of a drift. If the bracket has broken loose do not let it fall inside the body.
8. Using a drift to hold the bracket in position, button-hole weld the four holes. Have an air gun available so that it can be used to cool the welds rapidly (see Figure 3).
9. Grind the welds and apply primer followed by touch-up paint as necessary.
10. Refit the other parts removed in the reverse order.
11. Reconnect all ECU's and the battery. Check all electrical functions in the door.