Door Hinges Replacement
Front Right Door
April 24, 2020
46
This article will guide you through the door hinges replacement procedure. The door hinges usually fail after year of continuous use resulting wear and excessive play . Lifting the door up and down showed play which was translated in knocks and rattles when the vehicle is used on bumpy roads or under braking.
Items need:
- Hinges
- Primer and paint preferably in aerosol form
- Seam sealer
- Loads of patience and an assistant to help you (very important!)
Optionally the rubber weather strip protection at the lower part of the door can be replaced while at it. These seals usually wear out due to dirt and careless entry /exit of the passengers.
Door lower seals part numbers:
- front left door 60503897
- front right door 60503896
- rear doors 60503895
These are the correct part numbers for each hinge. Note that ePer DVD Rel. 16 has wrong part mumbers in the hinges description which one can find out after the mistake is done.
Hinges part numbers:
- Front left side door upper hinge 60595123 and lower hinge 60595124
- Front right side door upper hinge 60595124 and lower hinge 60595123
- Rear left side door upper hinge 60595125 and lower hinge 60595124
- Rear right side door upper hinge 60595126 and lower hinge 60595123
Apply two layers of primer.
Allow 24 hours between each layer so that the final paint dries.
Lets now dismantle the door card. Remove the handle horizontal cover.
Remove the blanking plug to expose the screw securing the armrest to the door.
Undo the three screws securing the armrest to the door card. The two screws secure the armrest to the door card whereas the smaller screw secures the handle slant cover to the armrest.
Remove the slant cover.
Undo the final two screws securing the armrest to the door card. Also unplug the power windows switch connector.
Remove the door mirror decorative triangle.
Remove the door check pin by tapping it from the bottom.
Pin is out and the door check is free. A new door check will be installed as this one is worn.
Remove the decorative foam.
These are the two screws securing the door check to the door.
That's the old door check.
That's the new one properly greased.
Remove the wiring. These are the electromagnetic locks connectors.
That's the power windows wiring and connectors.
Proceed removing the hinge bolts. Start from the upper hinge lower bolt.
Continue to the lower hinge upper bolt. Ask your assistant to hold the door and then undo the remaining bolts.
Door is out.
Hinges shown.
Put the door aside being careful to protect the bottom.
Tidy up the wiring.
Remove the existing wiring canal (optionally).
Install a new wiring canal. Usually these canals break on the locking notch.