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Par of door frame, 5D

Par of door frame, 5D

In the following description, the door frame is joined at the top edge in front of the C-pillar and at the lower edge by the rear wheel housing. The side panel must be removed when the complete door frame is replaced.


1. Position the car in an aligning bench and cross-measure if necessary.

2. Drill out the spot-welds and remove the reinforcement on the outside of the wheel housing. The reinforcement can be refitted if it is undamaged.


3. Grind down the seam-welds that secure the door frame to the front wheel housing.

4. Cut the door frame as illustrated, see Permitted joints . The reinforcement in the top of the D-pillar must not be damaged.


5. If the hinges are undamaged, cut the panel around the hinges.

If the hinges are damaged, remove them.

Drill out the spot-welds and tap loose the door frame. Drill out all welds in the lower flange of the lower edge.


6. Align any deformed sheet metal or panels.

7. Cut the spare part so that it will overlap the joint with about three centimetres. Cut out for the hinges if they are still fitted.

8. Fit the spare part and fixate with a couple of welding clamps.

9. Cut through the spare part and the body at the same time so that the joints can be welded edge-to-edge.


10. If the hinges have been removed:

Drill holes in the hinges as shown. Use 6 mm drill bit.


Rear doors, upper hinge:

A = 24.1, B = 30.2

Rear door, lower hinge:

B = 25.1, A = 30.2

11. Drill holes for the hinge mountings in the spare part according to the pre-stamped punch marks in the A and B-pillars.

12. Tighten the hinges with bolts and nuts.

13. Drill holes for plug-welding on the rear of the spare part.


14. Grind the surfaces to be welded on the spare part and the body.

15. Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zinkspray.

16. Fit the spare part and fixate with a couple of welding clamps.

17. Fit doors, front wing and bonnet, check and adjust the door openings.

18. Fasten the hinges with a couple of welds.

19. Remove the doors, front wing and bonnet.

20. Spot-weld the door frame.


21. Plug-weld the underside of the door frame.

22. All-weld the joints on the door frame.


23. Weld the hinges into place.


24. Remove the screws and nuts and weld the holes closed in the rear door hinges.

25. Plug-weld the door frame to the front wheel housing.

26. Weld on the reinforcement on the outside of the wheel housing.


27. Grind the welds.

28. Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.

29. Apply primer to all ground surfaces. Use Standox 1K Primer.

30. Seal joints and sheet metal flanges with sealant. Use Terostat 1K-PUR.

31. Apply anti-corrosion agent to the interior of the sill after painting. Use Terotex HV 400 or Mercasol 1.