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W163 (1997-2005)
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Removal and installation doors (Mercedes-Benz M-Class W163)

0
Contents: Rear doors ↡ Tailgate ↡
Front Door Installation Details (using the left door as an example)

Front Door Installation Details (using the left door as an example)


1. Front door installation details are shown in the illustration to which all references in the text refer.

2. Disconnect the contact block (X35/1 or X35/2).

3. Remove the screw (1) securing the door opening limiter to the A-pillar.

4. Remove the boot from the A-pillar.

5. Mark the position of the lower hinge plate on the door frame, then unscrew the bolts (2) securing it.

6. Ask an assistant to hold the door and unscrew the bolts (3) securing the upper hinge plate - also mark its position on the door frame in advance.

7. With the help of an assistant, remove the door assembly from the car, being careful not to damage the paintwork.

8. If any of the hinges needs to be replaced, remove it from the A-pillar.

9. Installation is carried out in the reverse order - ensure that the mounting marks applied during dismantling are correctly aligned and that the strut boot is correctly fastened, according to the size of the edge gaps (see Specifications) make sure that the door is positioned correctly in the body opening, and make the appropriate adjustments if necessary. Make sure that the lock latch operates properly.



Rear doors



Rear Door Installation Details (using the left door as an example)

Rear Door Installation Details (using the left door as an example)


1. The rear door installation details are shown in the illustration, to which all references in the text refer.

2. Disconnect the contact block (X35/3 or X35/4).

3. Remove the bolt (1) securing the door opening limiter to the B pillar.

(Full article available on the resource: MercedesMAN)

4. Remove the boot from the stand.

5. Mark the position of the lower hinge plate on the B-pillar, then unscrew the bolts (2) securing it.

6. Ask an assistant to hold the door and unscrew the bolts (3) securing the upper hinge plate - also mark its position on the rack in advance.

7. With the help of an assistant, remove the door assembly from the car, being careful not to damage the paintwork.

8. If any of the hinges needs to be replaced, remove it from the A-pillar.

9. Installation is carried out in the reverse order - ensure that the mounting marks applied during dismantling are correctly aligned and that the strut boot is correctly fastened, according to the size of the edge gaps (see Specifications) make sure that the door is positioned correctly in the body opening, and make the appropriate adjustments if necessary. Make sure that the lock latch operates properly.



Tailgate



Tailgate Installation Details

Tailgate Installation Details


1. The details of the installation of the tailgate are shown in the illustration, to which all references in the text refer.

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

3. Disconnect the electrical wiring connectors (1) and push them into the cable channel.

4. Disconnect the electrical wiring (2) from the rear wiper motor assembly. Release the harness from the door frame.

5. Fix the door in the open position and remove the sliding stop.

6. Having previously marked the position of the hinge strips, unscrew the screws (3) securing them to the door frame.

7. With the help of an assistant, remove the door assembly (4).

8. Installation is carried out in the reverse order - ensure that the mounting marks applied during dismantling are correctly aligned according to the size of the edge gaps (see Specifications) make sure that the door is positioned correctly in the body opening, and make the appropriate adjustments if necessary. Make sure that the lock latch operates properly.
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M-Class W163 / Doors and locks
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Removal and installation side door opening limiters
Removal and installation tailgate hinges
Removal and installation the gas-filled sliding tailgate stop
Removal and installation exterior door handles
Removal and installation interior trim panels of door assemblies
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W163 (1997-2005) 
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