Removing/Installing Door Panel Insert
Preparations1
Affected door panels
Only the insert should be replaced on the door panel when the insert has bubbles.
Replacements must be carried out on both of the front or rear doors.
Remove the affected door panels according to the method in VADIS.
Remove the retaining clips from the door panels.
2
Door panel
The illustration displays the components to be removed on the detached door panel when replacing the insert.
1: The loudspeaker grille (only applies to the front door).
2: The holder (for the switches).
Removal
3
Remove the loudspeaker grille, front panels
Warning!
Eye protection must be worn.
Remove the plastic rivets from the loudspeaker grille by using a grinder or chisel.
Plastic studs must be flush to the panel surface. Removing the grill starting at the lower rear (longest) mounting stud, by carefully pressing out the rivets to release the grille from the panel.
Drill a 3 mm hole in lower section of holder. (See illustration).
4
Drilling, rear panels
Drill in the clipholder on the rear door.
Drill a 3 mm hole (x 2) in lower section of holder. (See illustration).
5
Remove the holder for the switches
Heat the bracket connecting the grab handle frame and window switch holder (1).
Caution!
Too much heat will damage the bracket.
Insert a steel putty knife between the bracket and window switch holder. Hold the putty knife so that it heats up at the same time as the adhesive by moving the heat gun back and forth.
Heat until the adhesive becomes soft.
Push the steel putty knife into the adhesive, moving it from side to side to separate the bracket from the panel (see illustration).
Remove the steel putty knife.
6
Remove the holder
Repeat the preceding method between the window switch holder and door panel (2).
Repeat the preceding method on the front mounting for the grab handle (3).
Hint:
First heat the adhesive slightly. Cut away any excess adhesive to gain access using the steel putty knife under the holder. Remove the holder.
Remove the adhesive residue from the panel and holder. Clean the holes in the bracket.
If holder is distorted reshape the holder to it's original shape using additional heat if necessary.
Caution!
The fit must by verified.
Install the holder Check that the front mounting (3) is positioned flat against the panel.
7
Remove the insert
Front door:
Detach the insert at the loudspeaker cut out. Pull the insert backwards to remove it.
Rear door:
Make a cut in the center of the vinyl foil. Grip the insert at the cut and pull the insert towards the outer edge for complete removal.
8
Install masking tape
Install masking tape on the door panel around the cut out for the insert.
The masking tape must be positioned 2-3 mm into the insert attachment channel (1) to completely protect the panel when removing the foam.
9
Remove the foam from the insert
Warning!
Eye protection must be worn when cleaning/removing foam from panel.
Secure the door panel to the workbench with a clamp. Protect area between door panel and clamp by using a clean piece of cardboard or cloth.
Grind off any remaining foam from the door panel by using a drill grinding disc (3M) or steel brush if needed.
Clean off panel with compressed air.
All foam must be removed completely.
Replacing
Caution!
Step 10, 11, 12 and 13 must be completed within 8 minutes before the glue starts to cure.
10
Apply adhesive to the panel
Caution!
Use gloves when working with adhesives.
Distribute 2/3 of the adhesive glue tube onto the cleaned wooden surface.
Apply the adhesive using the 3M applicator, use a brush to assure the glue is evenly distributed.
11
Apply adhesive to the inserts
Distribute the rest of the contents of the tube (1/3) around the backside radius of the insert.
12
Distribute the adhesive
Spread the adhesive using the brush.
13
Install the insert
Caution!
Using your hand, press on the insert to assure proper contact between insert and panel.
Position the new insert on the adhesive covered surface.
Press the edges of the insert down into the attachment channel using a weatherstrip tool (9814071).
Start at the rear upper corner. Continue to the lower rear corner. Work your way forward alternating between upper and lower attachment channel finishing at the front top and lower corner.
14
Cut a slit in the cut out for the door handle and switch holder
Note!
Start and end cuts 4 m/m from edges.
15
Position of fixture
Position of fixture and the plywood piece on the insert.
1 Lower plate (thin plate)
2 Upper plate (plywood)
16
Press the insert into place, front panels
Caution!
Excessive pressure will cause marks in the insert material.
Secure the adhesive fixture using a clamp positioned in the center of the press tool and underneath of the workbench. Or use a piece of wooden board minimum size 18" x 40" 3/4".
Note!
Top edge of door panel must overhang work bench. Backside of door panel must be supported to a flat surface.
Note!
Turn clamp handle until upper wood piece comes in contact with lower plate. The insert must be compressed while the adhesive cures. Curing time depends on ambient temperature. Clamp should remain in place until adhesive is fully cured.
17
Press the insert into place, rear panels
Caution!
Use two clamps when pressing rear insert applying light pressure to the press plates.
After clamps are secured let stand for glue to cure. Leave clamp(s) in place, preferably for more than one half hour, to ensure proper curing.
Complete steps 1-17 on opposite panel before proceeding to step 18.
18
Complete the cut-out for the handle and the switches
Remove the press tools.
Complete the cut out for the switches and the grab handle in the insert using a sharp knife.
Leave 4 mm extra material around the openings (A). Remove the masking tape around the insert.
19
Install the holder
Install the holder in the cut out.
Assure correct fit between holder and door panel and adjust if necessary!
Install springs (see illustration in step 20).
Apply hot adhesive as outlined in picture. (1-2-3)
20
Fixation of holder, front door
Continue to press the bracket downwards while the adhesive cures.
Check that the holder is positioned correctly against the insert on the finished side.
If necessary heat the adhesive. Press the holder towards the panel.
Apply 3 Vise-Grip pliers to the center of holder to secure solid contact between bracket and holder.
21
Fixation of holder, rear door
Apply 2 Vise-Grip pliers to the center of holder to secure solid contact between bracket and holder.
22
Install the loudspeaker grille
Secure the loudspeaker grille. Apply hot adhesive to the studs and panel like a rivet.
Press the loudspeaker grille against the panel while the adhesive cures.
23
Installing foam blocks
Install the foam blocks (P/N 8650058) on the rear side of the door panel around the door handle opening, as outlined in the picture.
Install the clips on the door panel.
Reinstall the door panels according to the method in VADIS.
Verify fit between bezel and insert.
Test all the functions.
Clean the door panel. Use denatured alcohol.