WARNING
The doors are heavier than they appear. Support the door from the bottom and
use a helper during removal and installation. Do not allow the door to sag while
partially attached and do not subject the door to impact or twisting motions.
- Remove the door opening trim on Monteros.
- On all Monteros, removal of the cowl side trim (kick panel) just in front
of the door may be necessary for access to the wiring connectors.
- Disconnect the wiring harness (if any) running between the door and the
body. Carefully pull the wiring free of the body.
- Use a floor jack padded with rags or soft lumber to support the door at
its lower midpoint. Use a felt tip marker to outline the hinge position on
the door.
- Remove the upper and lower hinge covers if any are present. Remove the small
pin holding the door check arm in place.
- Have a helper support the door, keeping it upright at all times. Remove
the bolts holding the upper and lower hinge to the door. There will probably
be alignment shims between the hinge and the door panel; take note of their
location and placement for reassembly.
- Using two people, lift the door clear of the car.
- The door hinge may be removed from the body if necessary. On Pick-ups, the
bolts are concealed. Use special tool MB990900–01 or equivalent. This
is a specially shaped wrench built to do the job; removing the bolts will
be difficult without this tool.
To install:
- If the door hinge is removed from the body, reinstall it and tighten the
bolts to 25–40 ft. lbs. (35–55 Nm).
- Place the door in position and support it. Use the jack to fine tune the
position until the bolt holes and matchmark (hinge outline) align.
- Install the hinge bolts and nuts, and the alignment shims. Tighten the bolts
to 12–19 ft. lbs. (17–26 Nm).
- If all has gone well, the door should almost be in the original position.
Refer to the door adjustment procedures to align the door and body. It may
be necessary to loosen the hinge bolts and reposition the door; remember to
retighten them each time or the door will shift out of place.
- Once adjusted, connect the door check lever and install the pin. Install
the hinge covers if any were removed.
- Route the wiring harness(es) into the body and connect them to their leads.
- Test the operation of any electrical components in the door (locks, mirrors,
speakers, etc.) and test drive the car, checking the door for air leaks and
rattles.
| Fig. 1: Front and rear door assembly on the Monteros.
The front door assemblies on the Pick-ups are similar
|
- Remove the rear door scuff plate (sill plate).
- Remove the lower trim from the center pillar. Disconnect the wiring harness
running from the door to the pillar. Carefully pull the wire clear of the
pillar.
- Use a floor jack padded with rags or soft lumber to support the door at
its lower midpoint. Use a felt tip marker to outline the hinge position on
the door.
- Remove the small pin holding the door check arm in place.
- Have a helper support the door, keeping it upright at all times. Remove
the bolts holding the upper and lower hinge to the door. Using two people,
lift the door clear of the car.
- The door hinge may be removed from the body if necessary.
To install:
- If the door hinge is removed from the body, reinstall it and tighten the
bolts to 33 ft. lbs. (45 Nm).
- Place the door in position and support it. Use the jack to fine tune the
position until the bolt holes and matchmark (hinge outline) align.
- Install the hinge bolts and the alignment shims. Tighten the bolts to 16
ft. lbs. (22 Nm).
- The door should be in almost the original position. Refer to the door adjustment
procedures to align the door and body. It may be necessary to loosen the hinge
bolts and reposition the door; remember to retighten them each time or the
door will shift out of place.
- Once adjusted, connect the door check lever and install the pin. Install
the hinge covers if any were removed.
- Route the wiring harness(es) into the body and connect them to their leads.
- Install the lower pillar trim and the sill plate.
- Test the operation of any electrical components in the door (locks, speakers,
etc.) and test drive the car, checking the door for air leaks and rattles.
