Repair instructions
    Body Structures
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        Closures Service Procedures
        Bonnet Structure
        Bonnet Latch
        Door Structure
          DA-RM-02A052-05-001 - Remove/Install door
          DA-RM-02A052-05-002 - Remove/Install applique - Door
          DA-RM-02A052-05-003 - Remove/Install winglet - Door
          DA-RM-02A052-05-004 - Remove/Install aero duct - Door
          DA-RM-02A052-05-005 - Remove/Install blade - Door
          DA-RM-02A052-05-006 - Remove/Install stone deflector - Door
          DA-RM-02A052-05-007 - Remove/Install Mesh - Aero duct - Door
          DA-RM-02A052-05-008 - Replace Door
          DA-RM-02A052-05-009 - Remove/Install Access panel - Door
          DA-RM-02A052-05-010 - Remove/Install Support - Door - Secondary
        Door Hinge
        Door Latch
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        Tailgate/Engine Cover Structure
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Instructions
Body Panels and Closures / Closures / Door Structure / DA-RM-02A052-05-008 - Replace Door
Preparation work
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Care Point: Lower the door glass 150mm from fully closed before you disconnect the battery.
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Replace Door
1.  
Replace the door (1).
 
 
Care Point:
Do a check of the panel to see if the hem joints are sealed. You must seal the hem joints before you paint the panel.
Care Point:
If the hem joints are sealed you can continue the paint process and then install the components in reverse order.
 
2.  
Apply protection to the areas shown (1).
 
 
Care Point:
Make sure that you do not put tape or sealant on the top surface.
Care Point:
Make sure that the hem edge is fully taped.
Care Point:
Make sure that the tape is visually satisfactory.
Care Point:
When you apply cleaner, obey the manufacturer's flash times.
 
3.  
Clean the surfaces (1). Use Loctite 7064 Cleaner.
Put a continuous strip of 3M 2205 12mm Seam Sealer Tape on the areas shown (1).
 
 
Care Point:
Use a spatula to smooth the sealant over the hem.
Care Point:
Make sure that you fully seal the hem.
Care Point:
When you apply sealant, obey the manufacturer's flash times.
 
4.  
Clean the surfaces (1). Use Loctite 7064 Cleaner.
Put a continuous strip of 3M 2205 12mm Seam Sealer Tape on the areas shown (1).
 
 
Care Point:
Use a spatula to smooth the sealant over the hem.
Care Point:
Make sure that you fully seal the hem.
Care Point:
When you apply sealant, obey the manufacturer's flash times.
 
5.  
Apply sealant to the areas shown (1). The sealants that follow are permitted: Henkel Teroson MS9120, 3M 08684 Polyurethane Seam Sealer, Sika – Sikaflex 215, LORD – Versilok 500VLC.
Remove the unwanted sealant.
 
 
Care Point:
Use a spatula to smooth the sealant over the hem.
Care Point:
Make sure that you fully seal the hem.
Care Point:
When you apply sealant, obey the manufacturer's flash times.
 
6.  
Apply sealant to the areas shown (1). The sealants that follow are permitted: Henkel Teroson MS9120, 3M 08684 Polyurethane Seam Sealer, Sika – Sikaflex 215, LORD – Versilok 500VLC.
Remove the unwanted sealant.
 
 
Care Point:
Use a spatula to smooth the sealant over the hem.
Care Point:
Make sure that you fully seal the hem.
Care Point:
When you apply sealant, obey the manufacturer's flash times.
 
7.  
Apply sealant to the areas shown (1). The sealants that follow are permitted: Henkel Teroson MS9120, 3M 08684 Polyurethane Seam Sealer, Sika – Sikaflex 215, LORD – Versilok 500VLC.
Remove the unwanted sealant.
 
8.  
Remove the protection and continue the paint process.
 
9.  
Install the remaining components in reverse order.
 
   
   
   Note