ar7210y0500a

Remove/install front door

Type ar · topic 72.10 · version 0102 · 2019-11-13

Applies to: Body 400.899 in model 400.204/207/212/216/231/241/243/262/281

Where it sits

Function group 3 Body › 72 Doors › 72.10 Front door — Series 400 (models 204, 207, 212, 216, 231, 241, 243, 262, 281, 899)

EinPAS 35 Body/frame/detachable parts › 35.35 Door › 35.35.40 Front door — Series 400 (models 204, 207, 212, 216, 231, 241, 243, 262, 281, 899)

AR72.10-Y-0500A

Remove/install front door

13.11.2019

Body

400.899 in model 400.204/207/212/216/231/241/243/262/281

Remove/install front door

Y72.10-0001-09

Cabin Door Removal

1

Door glass regulator handle

4

Operator arm rest handle

2

Regulator handle seating rubber bush

5

Operator arm rest handle rubber bush

3

Operator arm rest handle cover

6

Door trim

Remove/install front door

Y72.10-0002-09

7

Inner open lever cover

11

Door glass regulator bush

8

Inner open lever cable

12

Glass mounting screw

9

Door glass regulator

13

Glass

10

Door glass regulator panel

14

Door regulator rail

Remove/install front door

Y72.10-0021-09

13

Glass

18

Glass weather strip

15

Glass runner

19

Handle lever lock

16

Glass runner beading

20

Door latch mounting

17

Glass weather strip lock

21

Dust seal

Remove/install front door

Y72.10-0022-09

22

Door latch

25

Outer handle mounting screw

23

Operator rest handle arm stopper

26

Door outer handle

24

Dummy cap

27

Striker plate

Remove/install front door

28

Door stopper assembly

29

Door assembly

30

Door trim beading

31

Lever lock

32

Inner open lever assembly

Y72.10-0023-06

Remove/install front door

33

Lever

34

Cable

35

Sealing cover

Y72.10-0024-06

Remove/install front door

Y72.10-0025-09

Key barrel removal

36

Lever lock plastic

39

Lever lock

37

Circlip

40

Spring

38

Plastic lock

41

Key barrel

Remove/install front door

42

Seating cover

43

Circlip

44

Hook

Y72.10-0026-06

Remove/install front door

Door key barrel refitment

40

Spring

41

Key barrel

42

Seating cover

43

Circlip

44

Hook

Y72.10-0027-06

Remove/install front door

36

Lever lock plastic

37

Circlip

38

Plastic lock

39

Lever lock

Y72.10-0028-06

Remove/install front door

35

Sealing cover

Y72.10-0029-01

Remove/install front door

Y72.10-0030-09

28

Door stopper assembly

32

Inner open lever assembly

29

Door assembly

33

Lever

30

Door trim beading

34

Cable

31

Lever lock

Remove/install front door

Y72.10-0031-09

22

Door latch

25

Outer handle mounting screw

23

Operator rest handle arm stopper

26

Door outer handle

24

Dummy cap

27

Striker plate

Remove/install front door

Y72.10-0032-09

13

Glass

18

Glass weather strip

15

Glass runner

19

Handle lever lock

16

Glass runner beading

20

Door latch mounting

17

Glass weather strip lock

21

Dust seal

Remove/install front door

Y72.10-0018-09

7

Inner open lever cover

11

Door glass regulator bush

8

Inner open lever cable

12

Glass mounting screw

9

Door glass regulator

14

Door regulator rail

10

Door glass regulator panel

Remove/install front door

Y72.10-0019-09

1

Door glass regulator handle

4

Operator arm rest handle

2

Regulator handle seating rubber bush

5

Operator arm rest handle rubber bush

3

Operator arm rest handle cover

6

Door trim

Remove/install

1

Remove door glass regulator handle (1) by removing the lock from regulator using screwdriver

Avoid scratch or damage the door trims while removal or refitment.

2

Remove regulator handle seating rubber bush (2) from door trim

3

Remove operator arm rest handle cover (3) using a screwdriver and pull out

4

Remove operator arm rest handle (4) from door by removing the bolts and pull out the other end

Operator arm rest handle to door

*BA60.80-Y-1055-01A

5

Remove operator arm rest handle rubber bush (5) from the door trim

6

Pull out the door trim (6) from the bottom side first and then remove from the top

7

Pull door inner open lever cover (7) manually

8

Manually unlock the door inner open lever cable (8) from open lever

9

Remove door glass regulator (9) from regulator panel

10

Remove door glass regulator panel (10) from the door

11

Remove door glass regulator bush (11)

12

Remove glass mounting screw (12) from door regulator rail

Slowly roll down the glass (13) to the bottom of the door.

13

Remove door regulator rail (14) from door

14

Lift glass (13) and hold it, remove the glass runner (15) mounting screw 3nos and remove glass from door using star screwdriver

15

Remove glass runner beading (16) from glass runner

16

Remove glass runner (15) from door using star screwdriver

17

Pull out the glass weather strip lock (17) using screwdriver and remove glass weather strip (18) from the door

18

Manually unlock the outer handle lever lock (19)

19

Remove door latch mounting screws (20) and dust seal (21)

20

Remove door latch (22) from door

21

Remove operator rest handle arm stopper (23)

22

Remove dummy cap (24) from door using a screwdriver

23

Remove door outer handle mounting screw (25) 1 no

24

Remove door outer handle (26)

25

Remove striker plate (27) from cabin

26

Remove door stopper assembly (28) from cabin pillar and door

Door stopper assembly to cabin pillar and door

*BA60.80-Y-1046-01A

27

Remove door assembly (29) from the door hinge

28

Remove door trim beading (30)

29

Remove lever lock (31) from door inner open lever assembly by using nose plier

30

Remove door inner open lever assembly (32) from door trim by using star screwdriver

31

Remove lever (33) from door latch

32

Remove cable (34) from door latch

33

Remove sealing cover (35) from door trim

Key barrel removal/refitment procedure

34

Remove lever lock plastic (36) from key barrel by using nose plier

35

Remove circlip (37) from key barrel by using screwdriver

36

Remove plastic lock (38) from key barrel by using screwdriver

37

Remove lever lock (39) from key barrel

38

Remove spring (40) from key barrel

39

Remove key barrel (41) from outer handle

40

Remove seating cover (42) from outer handle

41

Remove circlip (43) from lever lock

42

Remove hook (44) from lever lock

43

Side view mirror removal and refitment procedure

Remove/install complete outside mirror

AR88.70-Y-9000A

44

Install in the reverse order

Cabin Torque Chart

Number

Designation

Model 400.204/207/212/216/231/241/243/262/281 with body 400.899

BA60.80-Y-1046-01A

Door stopper assembly to cabin pillar and door

Nm

255

Cabin Torque Chart

Number

Designation

Model 400.204/207/212/216/231/241/243/262/281 with body 400.899

BA60.80-Y-1055-01A

Operator arm rest handle to door

Nm

30.5

Referenced documents