Table of contents: Removal the door ↓ Installation ↓ Adjusting the door position ↓ Gap sizes ↓ Longitudinal adjustment ↓ Adjustment relative to the center of… ↓ Adjustment with the lock bracket ↓
Back door 1. Door; 2. Bolt 8 Nm; 3. Door opening limiter; 4. Cover. Place on the mounting pin; 5. Dowel pin. 30 Nm; 6. Upper door hinge; 7. Bolt. 32 Nm; 8. Bolt. 45 Nm. The bolt is a so-called centering bolt, so adjusting the door with this bolt is usually not required. If adjustment with these bolts is necessary, they can be replaced with 1 of the same length and strength; 9. Bolt. 32 Nm; 10. Lower door hinge
Removal the door
Disconnect the plug connector to the A-pillar. Unscrew the bolt "2" of the door opening limiter. Remove the caps "1" and "3" from the mounting pins. Unscrew the mounting pins "4" from the upper and lower hinges.
Protect the paintwork around the door or side from damage. Carefully lift the door up and remove it from the door hinges.
Installation
Once the door has been installed, no adjustment is required.
Removal the door opening limiter 1. Door opening limiter; 2. Rubber tip; 3. Bolt 8 Nm; 4. Overlay; 5. Nozzle; 6. Bolt. 8 Nm
Bring the door glass to the "closed" position. Remove the door trim. Remove the lower speaker. Unscrew the "arrow" bolt of the door opening limiter.
Pull off the seal "1" of the door opening limiter in the door opening. Unscrew the bolts "arrows" and remove the door opening limiter "2" in the inward direction.
Move the rubber bushing "1" from the door opening limiter slightly towards "arrow A". Remove the rubber bushing from the door opening limiter "2" "arrow B".
Installation in reverse order.
Adjusting the door position
The "min" and "max" marks are used to check the lateral adjustment. The notch in the center of the template is used for height adjustment. The 0.6 mm offset is used to check the distance of the "B" pillar panels from the rear door to the front door.
Gap sizes
All dimensions are given in "mm". All dimensional tolerances are ±0.5 mm. The parallelism of the joint should not exceed 0.5 mm.
Size G = 5.5 mm. Size H = 4.5 mm. Size I = 3.5 mm
Remove the B-pillar trim. Remove the B-pillar connector block.
Longitudinal adjustment
Loosen the bolts "arrow B" at the top and bottom on the hinge and on the pillar A "pos. 1". Align the door "2" in the longitudinal direction. Tighten the screws "arrow B".
The hinge bolts on the door side are so-called centering bolts, so adjustment of the door with these bolts is usually not required. If adjustment with these bolts is necessary, they can be replaced with bolts of the same length and strength. Use the template "T40038/9" for adjustment. Set the template at a distance of "a" = 150 mm or "b" = 50 mm. When adjusted correctly, the template should fit against the roof and decorative strip at "point 1" (arrows), as shown in the figure. At "point 2" the lower side of the glass guide should be inside the groove.
Adjustment relative to the center of the car
Loosen the upper and lower bolts "arrow A" of the hinge. Align door "2" in the longitudinal direction. Tighten the screws "arrow A". Use template "T40038/9" to check.
Set the template at a distance of "a" = 150 mm or "b" = 50 mm. For the "min" position, points "1" and "3" should be adjacent. There should be no gap at point "2". For the "max" position, points "2" and "3" should be adjacent. There should be no gap at point "1".
Adjustment with the lock bracket
Adjustment using the lock bracket is performed only relative to the center of the car. Do not adjust the door height using the lock bracket, as this will damage the door lock. Loosen bolts "2". Move the lock bracket "1" so that the door is flush with the body contour. When adjusted correctly, the lock bracket should enter the door lock at the center. Tighten bolts "2".
(The original source of the article can be found on the website: «AudiManual.ru»)