REMOVAL & INSTALLATION
See Figure 1
140 and 160 Series and 1800 Series
- Remove the door panel (inner trim pad) following the instructions given in Door Panel Removal and Installation later in this section.
- Disconnect and, if necessary, remove the door stop mechanism. On 1800 series, simply drive or drill the pivot pin free at the pillar; the arm will then be free of the body. For 140 and 160 series, unbolt the bracket from the pillar.
- Open the door until the hinge bolts can be easily reached. Remember that the door stop is disconnected; don't open the door too far or you may damage paint or metalwork.
- Remove the retaining bolts holding the hinge to the body. Have an assistant hold the door and support it during removal. Once the door is free of the body, the hinges may be removed from the door if desired.
- When reinstalling, place the door in position and seat the hinge bolts finger tight. When the bolts are tight enough to hold the door in place, but loose enough to allow adjustment, close the door and check the alignment of the door seams. All the seams (gaps) should be even in width; the leading edge gap should be the same width as the trailing edge gap, and the weather strip should be evenly compressed around the door. The door is three-way adjustable on its hinges. The door may be moved fore-and-aft or up and down on its hinge mounts. If adjustment towards or away from the body is necessary, shims may be placed (or removed) between the hinge and the body.
- After the door is positioned correctly, tighten the mounting bolts and recheck the door fit.
- Install the door stop mechanism and check its function.
- Install the door trim pad.
See Figure 2
- Disconnect any wiring harnesses running into the door. This may be done either inside the door (remove the door liner) or under the dash inside the pillar. Make sure the wiring harness will not catch or bind as the door is removed from the car.
- On the earlier 200 series, remove the bolt holding the door stop bracket to the body. Later cars have the stop included in the lower hinge.
- Have an assistant support the door; loosen and remove the four bolts holding the hinge to the door.
- When reinstalling, have your helper position the door and install the hinge bolts. If the hinges were not removed from the body, the door should be in alignment. If not, the hinge-to-body bolts must be loosened just enough to allow the door to be moved into position. Tighten all the hinge bolts and check the final fit.
- If the door stop bracket was removed, reinstall it.
- Connect the wiring harness and check the function of electrical components in the door.
DOOR ALIGNMENT and ADJUSTMENT
See Figures 3, 4 and 5
As explained above, the primary door adjustments are carried out at the hinge bolts at the forward end of each door. Further adjustment for closed position and for smoothness of latching may be made at the latch plate or striker. This piece is located at the rear edge of the door and is attached to the bodywork of the car; it is the piece the door engages when closed.
Although the striker or latch plate is different on various models, the procedure for adjusting is the same:
- Loosen the large Phillips screw(s) holding the striker. Know in advance that these bolts will be very tight-an impact screwdriver is a very handy tool for this job-make sure you use the correct size bit.
- With the bolts just loose enough to allow the striker to move if necessary, hold the outer door handle in the released position and close the door. The striker will move into the correct location to match the door latch. Open the door and tighten the mounting bolts. The striker may be adjusted towards or away from the center of the car, thereby pulling the door tighter to the body if needed. The 140 and 160 series require a 1.5° inward angle on the front strikers and a 2.5° inward angle on the rear stickers.
Do not attempt to correct height variations (sag) by adjusting the striker.
- After the striker bolts have been tightened, open and close the door several times. Observe the motion of the door as it engages the striker; it should continue its straight-in motion and not deflect up or down as it hits the striker.
Check the feel of the latch during opening and closing. It must be smooth and linear, without any trace of grinding or binding during engagement and release.
It may be necessary to repeat the striker adjustment procedure several times (and possibly adjust the hinges) before the correct door-to-body match is produced.