Section of door frame, 5D
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Section of door frame, 5D
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In the following description, the door frame is joined at the top edge in front of the C-pillar and at the lower edge by the rear wheel housing. The side panel must be removed when the complete door frame is replaced.
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1.
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Position the car in an aligning bench and cross-measure if necessary.
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2.
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Drill out the spot-welds and remove the reinforcement on the outside of the wheel housing. The reinforcement can be refitted if it is undamaged.
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3.
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Grind down the seam-welds that secure the door frame to the front wheel housing.
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4.
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Cut the door frame as illustrated, see
Permissible joints
. Do not damage the reinforcement in the upper edge of the C-pillar.
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5.
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If the hinges are undamaged, cut the panel around the hinges.
If the hinges are damaged, remove them.
Drill out the spot-welds and tap loose the door frame. Drill out all welds in the lower flange of the lower edge.
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6.
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Align any deformed sheet metal or panels.
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7.
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Roughly cut the spare part so that it overlaps the joint by approximately three centimetres. Make cuts for the hinges if they are still in place.
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8.
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Fit the spare part and fixate with a couple of welding clamps.
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9.
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Cut through the spare part and the body at the same time so that the joints can be welded edge-to-edge.
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10.
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If the hinges have been removed:
Drill holes in the hinges as shown. Use 6 mm drill bit.
Rear doors, upper hinge:
A = 24.1, B = 30.2
Rear door, lower hinge:
B = 25.1, A = 30.2
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11.
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Drill holes for the hinge mountings in the spare part according to the pre-stamped punch marks in the B-pillar.
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12.
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Tighten the hinges with bolts and nuts.
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13.
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Drill holes for plug-welding on the rear of the spare part.
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14.
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Grind the surfaces to be welded on the spare part and the body.
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15.
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Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zinkspray.
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16.
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Fit the spare part and fixate with a couple of welding clamps.
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17.
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Fit doors, front wing and bonnet, check and adjust the door openings.
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18.
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Fasten the hinges with a couple of welds.
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19.
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Remove the doors, front wing and bonnet.
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20.
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Spot-weld the door frame.
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21.
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Plug-weld the underside of the door frame.
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22.
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All-weld the joints on the door frame.
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23.
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Weld the hinges into place.
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24.
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Remove the nuts and bolts and weld shut the holes in the rear door hinges.
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25.
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Plug-weld the door frame to the front wheel housing.
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26.
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Weld on the reinforcement on the outside of the wheel housing.
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28.
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Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
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29.
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Apply primer to all ground surfaces. Use Standox 1K Primer.
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30.
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Seal joints and sheet metal flanges with sealant. Use Terostat 1K-PUR.
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31.
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Apply anti-corrosion agent to the interior of the sill after painting. Use Terotex HV 400 or Mercasol 1.
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