Door seals require special care, because cracks in the seals lead not only to the tightness of the door, but also to increased flow noise during movement. The best way to care for seals is deer fat. Its only drawback is that it does not allow the seal to freeze to the body during the cold season.
To remove doors that have speakers and power windows, you must remove the door trim to disconnect their plugs. The same applies to the wires and hoses of the central lock.
1. Remove two hex bolts securing the lower and upper hinges on the door.
2. Remove the door. The hinges remain on the body.
3. Fit the newly installed door.
For the door to fit properly, the vehicle must be level on its wheels. If the door is fitted on a trestle-mounted vehicle, the adjustment will not be correct due to body compression under its own weight.
The gap between the attached parts front and rear must be 56.5 mm. Otherwise, the door must be centered. The door must also conform to the contour of the body and must not protrude or recede.
The upper front edge of the rear side doors overlaps the B-pillar by 14.5 mm. This distance is measured and checked with the door closed. Based on this distance, the remaining edges of the door are adjusted. The front edge of the front door should recede inward from the edge of the front wing by 0.5-1 mm. The same applies to the next gap. The rear edge of the front door should protrude outward by 0.5-1 mm relative to the front edge of the rear side door. Accordingly, the rear edge of the rear side door must protrude by the same distance relative to the rear wing.
4. Turn out for longitudinal adjustment of a door a back bolt of fastening of a door loop to a body, and also the carving plug which is under it.
5. Loosen the front bolt securing the door hinge to the body so that the door can be moved (see illustration).
6. Close the door and equalize the gap.
7. Carefully open the door and tighten the loosened front bolt securing the door hinge to the body.
8. Screw in the threaded bushing and tighten the rear bolt securing the door hinge to the body.
9. Loosen the bolts securing the door hinges to the body and move the door down or up if necessary to adjust the door height.
10. Tighten loose hinge bolts.
11. Loosen the bolts securing the door hinge to the door if adjustment of the front edge of the door is necessary.
12. Close the door and adjust the door gap.
13. Open the door and tighten the hinge bolts.
14. Loosen the locking finger of the door lock if necessary to adjust the position of the rear edge of the door (see illustration).
15. Close the door and adjust the door gap.
16. Open the door and tighten the door lock pin.
17. Make sure from inside the passenger compartment that the door seal is evenly adjacent to the opening.
18. Align the frame in the glass opening in the door. This adjustment is necessary if «casing» the door was incorrectly put on the inside.
19. Remove the door upholstery and loosen the four connecting bolts if necessary to level the opening.
20. Close the door.
21. Have an assistant insert the frame into the opening. It is better to push the frame deeper, because the sealing gum will squeeze it back out.
22. Tighten the connecting bolts. Tighten the top first, then the bottom. Tightening torque 20 Nm.
Door upholstery - removal
The order of removal of an upholstery of doors is given on an example of forward doors. On the remaining doors, the upholstery is removed in the same way.
23. Disconnect the power window handle. To do this, insert a screwdriver into the hole between the handle and the cover of the handle axis and press the lock (see illustration).
24. Remove the handle shaft cover.
25. Remove the Phillips head screw under the cover.
26. Remove switches (see relevant chapter).
Front doors without armrest switches
27. Turn out two screws of fastening of the bottom part of facing of an armrest and remove it. Under it are two screws that hold the upper part of the armrest trim (see illustration).
Under it are two screws that hold the upper part of the lining 1 of the armrest. 2 - the mechanism for adjusting the exterior rear-view mirrors. 3 and 4 - knobs for adjusting the exterior mirrors. Vehicles with four- and five-cylinder engines, as well as diesel engines
28. Remove these screws.
29. Remove the handle of mechanical adjustment of external rear-view mirrors. Use a screwdriver if necessary.
30. Feed the armrest to the rear edge of the door to bring its front part out of the mount. It takes a lot of effort here.
31. Lift the armrest up.
32. Release the mirror adjustment mechanism from the retaining brackets on the armrest.
Cars with six-cylinder engines, as well as diesel engines from 7/93
33. Remove the three 4mm socket head screws on the underside of the armrest (see illustration).
34. Remove the armrest, disconnect the plug and remove the switch panel. (see illustration 7.33).
35. Disconnect the armrest holder.
All models
36. Pull the inside door handle towards you.
37. Remove the Phillips head screw that secures the interior handle trim. The screw is under the door handle.
38. Feed the handle facing forward and remove it.
39. Remove the clamp on the pull on the lock side of the handle and disconnect the pull (see illustration).
40. Turn out in the top part of a door two screws of fastening of an upholstery.
41. Disconnect the sealing gum opening for the door glass, covering the door upholstery.
42. Remove the door trim by hitting it with the palm of your hand to release it from the fasteners (see illustration).
7.42 Turn out the specified screws and remove a door upholstery.
1 and 2 - top side screws
3 and 4 - screws for fastening the upper armrest pad
5 - screws for fastening the lower part of the armrest
6 - power window handle
Before installing the door upholstery, secure the rubber inserts. To make them easier to enter, lubricate them with Vaseline or silicone paste.
43. Make sure that the lock release button fits exactly into the hole in the upholstery.
The outer part of the door - replacement
In case of damage to the outer part of the door, it must be replaced. We recommend varnishing the new outer part of the door before installation.
44. Remove the door upholstery.
45. Remove the door and lay it with the outside on a soft lining (styrofoam, woolen blanket).
46. Disconnect the lock leash from the inner lock handle rod.
47. Turn out four connecting bolts by which fasten «casing» doors and interior (see illustration).
7.47 Door with padding removed
1 - window mechanism bolts
2, 5 - window guide bolts
3, 6 - connecting bolts of the outer and inner parts of the door
4 - a bolt of fastening of an armrest of a door.
Door lock - removal
48. Remove the two 6mm socket head screws.
49. Give the castle a little back. This will provide access to the leashes of the lock (see illustration).
50. Disconnect the rods from the inner handle of the lock and from the lock switch button.
51. Rotate the lock 90°to allow access to the rods from the outside handle.
52. Remove the inner door upholstery to provide easy access to the details of the lock when installing it.
53. In order to fix the rod from the inner handle on the lock leash, flip the leash on the lock with a screwdriver and hold while attaching the rod.
External handle of the lock - removal
54. Remove the door upholstery.
55. Unscrew in the door opening, acting from its inside, a T25 socket head bolt (see illustration).
Approximately at the level of the door lock in its cavity there is a locking lever. Insert your hand into the cavity of the door and turn the leash approximately 65°in the opposite direction from the lock.
Now the handle can be removed by pulling it inward. Remove the switch of the lock and an overlay, having submitted outside. Rotate the cover a little.
56. Disconnect the lock drive leash.
The rotary switch of the lock on the external handle - removal
57. Remove the outer handle.
58. Insert the key into the switch so that the cylinders and springs do not fall out when the switch is removed.
59. Remove the thrust ring at the rear end of the switch.
60. Remove the lock drive pin and spring. Before doing this, mark their position to facilitate subsequent assembly.
61. Remove the rotary switch from the facing.
62. Coat the new rotary switch before installing it with protective grease to prevent rust.
Power windows - removal
63. Remove the door upholstery.
64. Turn out four connecting bolts by which the internal and external parts of a door are fastened and remove internal part. The outer part remains hanging on hinges.
65. Remove a persistent ring of fastening of glass to a window regulator. Remove glass.
66. Turn out bolts of fastening of the mechanism of raising of glasses. For power windows, nuts must be removed instead of bolts. Power windows and their mechanism (electric windows - electric motor) are one piece and must be removed or replaced as a set.
Door glass - replacement
67. Remove windows.
68. Remove the glass seals on the rails.
69. Replace the seals after installing the glass. The distance from the bottom edge of the gasket to the bottom edge of the guide should be 25 mm.
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