Removal, installation and adjustment of doors (Mercedes-Benz G-Class W463)

Front doors

Removal and installation

Door assembly

1. On models with the corresponding configuration (code ET2), activate the service mode of the TELE AID emergency call system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).

2. Turn on the auxiliary battery and connect it to the standard battery, then disconnect the negative cable from the latter.



3. Remove the corresponding side turn signal repeater (E22/1 or E22/2) and disconnect its electrical wiring connector (1).

4. Remove the cover on the left or right (depending on which door will be removed) under the instrument panel (see Section Removal and installation lower instrument panel covers).

5. Separate the carpet (2) from the A-pillar in the front footwell.

6. On the A-pillar, in the corresponding footwell, disconnect the door electrical wiring connector (X35/41 or X35/42).

7. Remove the corresponding contact elements from the ground potential equalising connection block (3).

8. On the A-pillar in the footwell, remove the ground wire of the side turn signal repeater.



9. Release the rubber pass-through sleeve (4) from the door assembly and from the A-pillar - a damaged sleeve must be replaced.

10. Release the door wiring harness from the A-pillar - try to remember the route of the wiring harness.

11. Support the door and remove the screws securing the lower (5) and upper (6) hinges.

12. Remove the door.

13. Installation is carried out in reverse order - do not forget to adjust the door (see below).

14. On models with the corresponding configuration (code ET2), deactivate the service mode of the TELE AID system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).

15. Finally, read the DTC codes and clear the on-board diagnostic system memory using the STAR DIAGNOSIS scanner (6511 1801 00) (See Chapter Engine electrical systems).

The door is disassembled

1. Perform procedures 1 and 2 (see above).

2. Remove the door interior trim panel (see Section Removal and installation interior trim of door assemblies).

3. Disconnect the electrical wiring from the door speaker.

4. Remove the door control module (see Chapter On-board electrical equipment).

5. Carefully remove the door's film insulation covering - if damage is detected, the film must be replaced to prevent moisture from entering the interior.

6. Disconnect the connector (1) of the door rear view mirror wiring.

7. Release the door electrical wiring connectors (2) from the clamps and disconnect them - try to remember the route of the wiring harness.

8. Release the rubber pass-through sleeve (3) from the door assembly and from the A-pillar - a damaged sleeve must be replaced.

9. Release the wiring harness from the door assembly.

10. Support the door and remove the screws securing the lower (5) and upper (4) hinges.

11. Remove the door.

12. Installation is carried out in reverse order - do not forget to adjust the door (see below).

13. On models with the corresponding configuration (code ET2), deactivate the service mode of the TELE AID system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).



14. Finally, read the DTC codes and clear the on-board diagnostic system memory using the STAR DIAGNOSIS scanner (6511 1801 00) (See Chapter Engine electrical systems).

Adjustment

1. Loosen the screws securing the lower (1) and upper (2) hinges. Also loosen the screws securing the locking wedge (3).

2. Adjust the position of the door in the body opening, ensuring that the gap is the same along the entire perimeter, and that the surface of the door in the closed position is flush with the surface of the surrounding body elements - if necessary, place adjusting shims under the hinges or remove them.

3. Having achieved the desired result, tighten the screws securing the hinges (4 and 5) and the locking wedge (3).

4. Lubricate the lock mechanism and make sure the door closes smoothly.

5. Finally, touch up the screw heads.

Rear doors

Removal and installation

The procedure is similar to that described above for the front doors, except for the actions associated with disconnecting the electrical wiring of the door mirrors and turn signal repeaters.

Adjustment

The procedure for adjusting the rear doors is completely similar to that described above for the front doors.

Tailgate (models Universal)

Removal and installation

1. Perform the procedures in paragraphs 1 and 2 of the Front Doors subsection.



2. Remove the spare tire.

3. On models with the corresponding configuration (codes V53 and V57) remove the luggage compartment lid (A).

4. On models with the corresponding equipment (code V53), remove the cover (B) of the side storage compartment, then unscrew the fastening screw (D) and separate the storage compartment (C) from the rear pillar.

5. Remove the protector (4) from the left edge of the door opening from the rear pillar.

6. Remove the left rear pillar trim panel (E).

7. Release the retainer (1) of the door wiring harness.

8. Release the return spring (2).

9. Unscrew the fastener of the electrical wiring pass-through tube (5).

10. Remove the door interior trim panel (see Section Removal and installation interior trim of door assemblies).

11. Disconnect the rear window wiper motor wiring connector - mark the wires, try to remember the route of the harness.

12. Disconnect the rear window heating element wiring connector - mark the wires, try to remember the route of the harness.

(Information copied from the website Mercedesman.ru)

13. Release the electrical wiring from the door assembly.

14. Release the fastener and detach the door opening travel limiter (6) from the door.

15. Holding the door, unscrew the screws securing its upper (7) and lower (8) hinges.

16. Remove the door.

17. Installation is carried out in reverse order - do not forget to adjust the door (see below).

18. On models with the corresponding configuration (code ET2), deactivate the service mode of the TELE AID system (see Section Activation/deactivation of the service mode of the TELE AID emergency call system).

19. Finally, read the DTC codes and clear the on-board diagnostic system memory using the STAR DIAGNOSIS scanner (6511 1801 00) (See Chapter Engine electrical systems).

Adjustment

1. Remove the ball joint (1) from the tailgate.

2. Remove the lock striker (2) from the tailgate.

3. Remove the latch (3) from the body element.

4. On models 463.246/250, perform the procedures in paragraphs 6 and 7 and remove the battery cover.

5. Remove the inner trim of the tailgate (see Section Removal and installation interior trim of door assemblies).

6. After releasing the fasteners, adjust the position of the door in the body opening in accordance with the same criteria as for the side doors (see paragraph 2). Also adjust the position of the striker (6) by tapping it with a hammer while the fastener is loosened.

7. Installation of components is carried out in the reverse order of their dismantling - do not forget to adjust the position of the striker (2) and the latch (3) accordingly.

Drop side (convertible models)

Removal and installation

1. Turn the spare wheel holder to the side.

2. Open the tailgate (2).

3. Open the cover (5), release the latches and remove the insert (6) of the tool compartment.

4. Disconnect the connector (M14/7x1) of the single lock actuator electric motor.

5. Using a steel wire or a narrow screwdriver, remove the terminals (7) from the connector.

6. On the left side of the tailgate frame, disconnect the terminal (8) from the connector (9) of the contact sensor-switch - again use the wire or a narrow screwdriver, having first removed the plastic protective cap (10) and unlock the lock.

7. Release both wiring harnesses (11) from the side (2).

8. Close the cover (5) of the tool compartment.

9. Unscrew the screws (1) securing the side opening travel limiters - the screws must be replaced without fail.

10. Close the side - try not to pinch the electrical wiring (11).

11. Remove the hinge screws (3), then open the side (2) and remove it from the vehicle - use the help of an assistant.

12. Installation is carried out in the reverse order - to facilitate the installation of the electrical wiring, lubricate the bushings with a soap solution.

13. Finally, adjust the side (see below)

Adjustment

1. Release the spare tire bracket holder (1) and remove it from the ball head (2).

2. Loosen the hinge bolts (3).

3. Fold back the side and loosen the locking wedge screws (4).

4. Tighten bolts (3) and (4) so that it is possible to adjust the position of the components they secure by tapping with a hammer.

5. Close the side panel and make sure that the gaps (A, B and C) of its fit in the body opening are identical. Also make sure that the upper edge of the side panel (D and E) closes flush with the surrounding body panels.

6. If necessary, adjust the fit of the hinges and the locking wedge.

7. Finally, do not forget to tighten the mounting bolts.