57-1 Front door Tools Special tools, workshop equipment, testers, measuring instruments and auxiliary items required T 10011 Socket insert T 10072 Socket wrench T10118 Assembly tool 3320/2 Box spanner 3320/3 Box spanner 3410 Socket insert 57-2 Assembly overview Note: The hinge bolts must always be replaced if loosened. The dash panel must be removed to remove and adjust the upper door hinges. 1 - Door Removing and installing Page 57-7 2 - Door handle with base Removing and installing Page 57-15 3 - Lock cylinder housing Removing Page 57-13 4 - Cover cap 5 - Screw 20 Nm 6 - Locking button Removing and installing Page 57-29 57-3 7 - Locking rod 8 - Bellows 9 - Screw 20 Nm 10 - Lock plate 11 - Door lock Removing and installing Page 57-18 12 - Bowden cable 13 - Interior release handle Removing and installing Page 57-26 14 - Multi-point socket head bolt M8 x 28 20 Nm + 1/4 turn further (90 ) Always replace bolt after loosening 57-4 15 - Multi-point socket head bolt Only remove this bolt from hinge to remove door M8 x 28 20 Nm + 1/4 turn further (90 ) Always replace bolt after loosening 16 - Door hinge with arrester Hinge is split 17 - Multi-point socket head bolt M8 x 28 Install from inside vehicle Remove A pillar lower trim Repair Manual, Body Interior, Repair Group 70; Pillars and side trims 20 Nm + 1/4 turn further (90 ) Always replace bolt after loosening 57-5 18 - Multi-point socket head bolt M8 x 28 20 Nm + 1/4 turn further (90 ) Always replace bolt after loosening 19 - Multi-point socket head bolt M8 x 28 20 Nm + 1/4 turn further (90 ) Always replace bolt after loosening 20 - Cover cap 21 - Grub screw 23 Nm 22 - Door hinge Hinge is split 57-6 23 - Multi-point socket head bolt M8 x 22 Install from inside vehicle To loosen or tighten the bolt, remove and install dash panel Repair Manual, Body Interior, Repair Group 70; Dash panel 20 Nm + 1/4 turn further (90 ) Always replace bolt after loosening 24 - Multi-point socket head bolt M8 x 28 20 Nm + 1/4 turn further (90 ) Always replace bolt after loosening 57-7 Door, removing and installing Note: Various screws are used to secure the door hinge. There are two box spanners for this, bit 3320/2 (Emden production only) as well as 3320/3. - Remove A pillar lower trim -5Repair Manual, Body Interior, Repair Group 70; Pillars and side panel trims; Removing A pillar lower trim - Pull bellows -3- off A pillar. Guide electrical cables out of pillar through hole -arrow-. - Lever out cap -1- and remove grub screw -2from upper hinge. Tightening torque: 23 Nm 57-8 - Remove lower bolt -4- from hinge. Tightening torque: 20 Nm + 1/4 turn further (90 ). Note: Always replace this bolt. - Lift door out of door brackets upwards. 57-9 Door, adjusting To ensure a correct door adjustment the door hinges on the pillar must be loosened. Other measures such as raising the door upwards have no effect. Over pressuring thereafter will again cause the door to sack. Use door adjustment wrench 3320 with box spanner 3320/2 (Emden production only) or box spanner 3320/3. If there is a requirement to loosen the door hinge on the upper A-pillar from the interior, socket 3410 can be used. The dash panel must be removed for this. Repair Manual, Body Interior, Repair Group 70; Dash panel; Removing and installing dash panel. 57-10 Door handle and door lock, assembly overview 1 - Door lock Door lock can only be removed in conjunction with the subframe Removing and installing Page 57-18 Cover - 4 - was introduced as a running change in production for the lock. It is clipped onto the lock and must be reinstalled or retrofitted when replacing the door lock. 2 - Cable Lock release 3 - Angle bracket Bolted and riveted to door lock Does not belong to door lock delivery casing 57-11 4 - Cover Does not belong to door lock delivery casing Must be re-installed or retrofitted when replacing door lock Retrofit for all vehicles 09.99 5 - Mounting bracket Removing Door handle, lock cylinder housing and subframe have been removed - Remove Phillips-head screw - 6 -, slide mounting bracket slightly to rear and remove from door. 6 - Phillips-head screw 7 - Door handle with backing plate Removing and installing Page 57-15 57-12 8 - Concealment cap 9 - Lock cylinder housing Removing Page 57-13 Lock cylinder is not available as an individual replacement part 10 - Base plate 11 - Socket-head bolt T 10011 Socket insert T 10072 Socket wrench By loosening this bolt, locking mechanism for lock cylinder housing - 9 - is disengaged and may be removed from mounting bracket - 5 Bolt - 11 - must not be threaded in without lock cylinder housing installed. Lock mechanism ring may fall into door 57-13 Lock cylinder housing, removing and installing Removing - Lever out cover cap -3-. - Pull door handle -1- and hold. Unscrew screw -3- onto stop with socket insert T 10011 (socket wrench T10072 has been introduced gradually). This releases the lock cylinder housing. Note: Unscrewing the bolt too far may result in the locking ring releasing from the mounting bracket and falling into the door. - Pull lock cylinder housing -2- out of door handle mounting bracket at right angles. 57-14 Installing - Fit lock cylinder housing in door handle mounting bracket at right angles. - Fit screw in mounting bracket and tighten with socket wrench. The door handle locates in the lock cylinder housing with an audible click. Note: Press door handle and lock cylinder housing against door panel when assembling. - Then perform remaining installation in reverse order. Then perform a functional check always as an incorrectly fitted and adjusted Bowden cable cannot open the door. 57-15 Door handle, removing and installing Removing and installing lock cylinder housing Page 57-13 . Removing - Unclip clip -1- from door handle. - Swing door handle out of door. Installing for vehicles up to Vehicle Identification Number (VIN) 3B XE 059 999 and to 3B XP 077 999 - Swing door handle into door. - Pull clip -1- into panel cut out and engage in door handle -2-. Note: When assembling clip, do not pull lock operating lever -3- and press door handle -2- onto door panel. Installing lock cylinder housing Page 57-13 Then perform functional check. 57-16 Installing for vehicles from Vehicle Identification Number (VIN) 3B XE 060 000, and 3B XP 075 000 - Guide assembly tool T10118 into door through opening in the inner door plate. - Illuminate the inner part of door using a flashlight for better view. - Hook assembly tool into spring (arrow -A-). - Engage spring into door lock by pulling assembly tool (arrow -B-). Activation lever is now locked. 57-17 - Swing door handle into door. - Pull clip -1- into panel cut out and engage in door handle -2-. Note: Press door handle -2- against door panel when assembling. Installing lock cylinder housing Page 57-13 Then always perform a functional check with the door open as an incorrectly fitted and adjusted Bowden cable cannot open the door. 57-18 Door lock, removing and installing The window lifters, the door lock and the loudspeaker are secured to the assembly carrier. The door lock can only be removed in conjunction with the assembly carrier. The assembly carrier can only be removed when the door window clamping brackets of the window lifter are unscrewed. To do this lower door window to the height of the assembly holes in assembly carrier and loosen clamping brackets. If electrical windows cannot be lowered then the cause of the fault must be determined first. To do this interrogate convenience locking systems fault memory (address word 46) with fault reader V.A.G 1551 Repair Manual, Body On Board Diagnostic (OBD), Repair Group 01; Convenience system; Interrogating fault memory. If a fault is present then proceed as described on pages Page 57-20 and Page 57-21 . 57-19 Removing All vehicles - Removing front door trim Repair Manual, Body Interior, Repair Group 70; Removing and installing door trim - Removing lock cylinder housing 13 . - Unclip clip -1- from door handle. - Lever out cover cap -1-. Page 57- 57-20 Vehicles with electrically operated windows Note: If motors fail, proceed as follows. - Unscrew bolts -1- (Qty. 4). - Pull housing -2- off window motor. Bosch electric window lifter motor - Pull armature -1- off window motor -arrow-. - The door window can now be pushed down to the height of the assembly holes in the assembly carrier. Note: The motor must not be reused. 57-21 Siemens electric window lifter motor - Unscrew bolts -1- (Qty. 4). - Pull housing -2- off window motor. Note: The motor must not be reused. - The door window can be lowered down to the height of the assembly holes by turning the armature -1-. 57-22 All vehicles - Lower door window until door window securing bolts are accessible. - Loosen bolts -2- and press clamps apart. - Push window upward and secure in position (e.g. with adhesive tape). - Disconnect all connections -arrows-. 57-23 - Lever out cover cap -3-. - Unscrew bolts -2- Tightening torque: 20 Nm. - Unscrew bolts -arrows-. Pull top of assembly carrier off door, lift and take out of door towards hinges. - Turn assembly carrier and pull connector off door lock. - Then unclip clips for electrical cables on back of assembly carrier. 57-24 - Drive out clips -1- with a drift. - Unclip cable -2- from clip -1-. - Lever door lock with retaining bracket off assembly carrier using a screwdriver -3-. Note: The retaining bracket is not part of the items supplied with the door lock. Secured to door lock with a bolt and a pop rivet. 57-25 - Unclip securing rod -1-. To do this turn door lock in direction of arrow. - Unclip cable -2-. - Turn cable nipple through 90 and take out from eye. Installing Notes: When replacing door lock, make sure that the cover (Item - 4 -, Page 57-11 ) is re-installed or retrofitted on door lock. Retrofit cover for all vehicles 09.99. - Insert assembly carrier in door. - Fit bolts and tighten in the prescribed sequence. Tightening torque: 8 Nm. - Loosen clamps, press door window -1- into the window guides -arrowand tighten clamp with bolts -2- (10 Nm). Install remainder in reverse order. Then perform functional check. 57-26 Inner release handle, removing - Removing front door trim Repair Manual, Body Interior, Repair Group 70; Removing and installing door trim - Remove cross head screw -1-. - Unclip switch -2- for electric windows. - Unclip door inner release -arrows- and take out from door trim. 57-27 Door seals Door seals are fitted in series production with a sealant, they are placed on the door flange and then rolled on. Note: If they are removed the sealant will spread on the inside of the seal and the flanks will be bent out slightly. If the seal is then refitted there is no guarantee that it will fit tightly and seal. Therefore each seal which is removed completely should be replaced by a so called "hammer blow" seal. When seals have been partially removed squeeze the flanks together before refitting. 57-28 Door inner seal, removing and installing - Pull door inner seal off body flange. - When installing the door inner seal, start at upper radius of the door cut-out -1-. 57-29 Locking knob for locking rod, removing and installing The description for removing and installing the locking knob must be adhered to. Not observing the sequence, may unscrew the locking rods in the front door locks and the relays in the rear doors or damage the mountings. 57-30 Removing Front right and rear left doors - Release locking knob by turning 180 anti-clockwise. - Take locking knob off upwards. Installing Front right and rear left doors - Fit locking knob onto locking rod with mark -small dot on top- towards vehicle interior. - Press locking knob onto locking rod until the fluted section is flush with the height of the door trim. - Then turn the locking knob 180 anti-clockwise. Locking knob in "locked" condition can project approx. 0...2 mm above door trim. 57-31 Removing Front left and rear right doors - Release locking knob by turning 180 clockwise. - Take locking knob off upwards. Installing Front left and rear right doors - Fit locking knob onto locking rod with mark -small dot on top- towards vehicle interior. - Press locking knob onto locking rod until the fluted section is flush with the height of the door trim. - Then turn the locking knob 180 clockwise. Locking knob in "locked" condition can project approx. 0...2 mm above door trim.
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