Doors - removal and refitting

Front door Pre-1986 models
Removal
1 Open the door fully and support its lower edge on a jack or blocks covered with a pad of cloth to prevent scratching.

2 Unscrew the two bolts which hold the check arm bracket to the body and disconnect the arm.

3 Remove the scuff plate from the sill at the bottom of the door aperture.

4 Unclip the lower cowl side trim panel, and where fitted remove the radio speaker (Chapter 12).

5 Remove the heater duct.

6 On cars with electrically operated windows, mirrors or central locking, disconnect the wiring multi-plug from inside the passenger compartment and feed the wires through the aperture in the pillar.

7 Unbolt the door lower hinge from the body pillar (see illustrations).

12.7a Front door lower hinge nuts (arrowed)
12.7a Front door lower hinge nuts (arrowed)

12.7b Door hinge assemblies - pre-1986 models
12.7b Door hinge assemblies - pre-1986 models

A Rear door B Front door

8 Unbolt the upper hinge from the body pillar, then lift the door from the vehicle.

Refitting
9 Refitting is a reversal of removal, but do not fully tighten the hinge bolts until the alignment of the door within the body aperture has been checked.

1986 models onwards
10 The procedure is as described previously in this Section for pre-1986 models, but it is necessary to extract the pin from the upper hinge rather than unbolting the hinge from the pillar. To do this, ideally special tool 41-018 is needed, but a suitable alternative can be made from a piece of metal with a U-shaped cut-out which will engage under the head of the pin (see illustrations).

12.10a Front door upper hinge pin (arrowed) on 1986 models onwards
12.10a Front door upper hinge pin (arrowed) on 1986 models onwards

12.10b Front door upper hinge pin removal using special tool - 1986 models
12.10b Front door upper hinge pin removal using special tool - 1986 models onwards

Strike the tool downward to remove the pin. When refitting, tap the pin upwards into place.

Rear door
Saloon and Estate models 11 The operations are similar to those described for the front door on pre-1986 models, except that the centre pillar trim panels must be removed for access to the hinge bolts.

Van models
Removal
12 Begin by opening the door to its full extent and supporting it on a jack or blocks, with a pad of cloth used to prevent scratching.

13 Disconnect the check strap from its lower edge.

14 Unbolt the hinges from the door and remove the door from the vehicle.

Refitting
15 Refitting is a reversal of removal, but do not fully tighten the hinge bolts until the alignment of the door within the body aperture has been checked.

    See also:

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