72 - 2101 Dismantling and assembling hinged door (door removed)
1 Window seal Check | 14 Inside door handle | |
2 Outside door handle | 15 Screw with washer | |
3 Insert | 16 Guide rail | |
4 Window rail Check | 17 Window lifter Check; grease | |
5 Hinged door | 18 Hexagon bolt | |
6 Window | 19 Guide rail | |
7 Internal lock button | 20 Allen bolt 25 Nm | |
8 Cross-head screw | 21 Door arrester Check | |
9 Door lock Check; grease | 22 Serrated washer Replace | |
10 Screw (micro-encap.) Replace | 23 Countersunk Allen bolt 25 Nm | |
11 Screw (micro-encap.) Replace | 24 Hinge | |
12 Cover cap | 25 Collared hexagon bolt | |
13 Pull rod | 26 Cover cap | |
Shop-made tool
Board to facilitate assembly of window rail.
Dimensions as per drawing. Material: hard wood or plastic
5 thick
100
460
Dismantling
1 Pull off cover caps on hinge fixtures. Remove hinges.
2 Unscrew mirror bracket with mirror.
3 Unscrew internal door lock button.
4 Pull off cover cap and unscrew retaining screws for door handle, both those behind the caps and those on the edge of the door.
5 Unscrew retaining screws for window guide. Push window guide slightly to one side.
6 Unscrew retaining screws from window lifter.
7 Push down window and pull window lifter out of window rail. Remove window, window lifter and guide rails downwards.
8 Unclip inside door handle.
9 Pull off cover cap on door lock fixture, unscrew door lock and remove together with inside door handle. To do this, turn rotary tumbler downwards until lock engages.
10 Remove door arrester.
11 Remove window rail, triangular window and door seal.
Assembling
12 Pull in triangular window.
13 Install door seal.
Note
Coat seals with lubricant prior to assembly.
14 Pull in window rail.
14.1 Pull in cord (approx. 2m long with dia. 2mm) as illustrated.
14.2 Suspend cord ends in duct and press window duct profile onto flange.
Note
Note installed position of window rail. The longer end of the window rail points forwards.
14.3 Install long end of window rail, starting in the middle at the top of the window opening. Continue with the short end in the same way.
14.4 Insert auxiliary tool into window duct and pull out cord. Remove auxiliary tool and check whether the profile is properly seated.
14.5 Use a wedge to lock the profile in place all the way round.
15 Install door arrester.
16 Install door lock and inside door handle. Press on cover cap.
Note
To prevent rattling noise from the handle linkage, ensure that the cellular rubber cushions are glued to the inside door panel.
17 Introduce window into window rail from below and push up to the halfway position.
18 Insert window lifter into window lifter rail and screw in place.
19 Attach crank handle and crank window to the fully closed position, install guide rails and screw in screws, but do not tighten.
20 Crank window to the fully open position. Adjust guide rails and tighten screws.
21 Install outside door handle and internal lock button. Press on cover cap.
22 Screw on mirror bracket with mirror.
23 Attach hinges; only screw in one screw per hinge, but do not tighten.