connector rear BMW 325i 1992 E36 Owner's Guide

260-
4
DRIVESHAFT

CAUTION
-

The
maximum
allowable
change
in
height
of
the

center
bearing
or
transmission
support
using

shims
is
3
mm
(0
.12
in
.)
.

Driveshaft,
removing

WARNING
-

"
Be
sure
the
wheels
are
off
the
ground
before
re-

moving
the
driveshaft
.
Set
the
parking
brake
be-

fore
removing
the
driveshaft
.

"
Once
the
driveshaft
has
been
removed,
the
vehi-
cle
can
roll
regardless
of
whether
the
transmis-
sion
isin
gear
or
not
.

"
The
driveshaft
fs
mounted
to
thetransmission
and
final
drive
with
self-locking
nuts
.
These
nuts

are
designed
to
be
used
only
once
and
should
be

replaced
during
reassembly
.

1.
Disconnect
oxygen
sensor
electrical
connectors
and
remove
complete
exhaustsystem
.
See
180
Exhaust

System
.

4
.
Remove
driveshaft
mounting
bolts
.
See
Fig
.
3
.
Discard

old
nuts
.

JG

Fig
.
3
.



Front
driveshaft
totransmission
mounting
bolt
being
re-
moved
.
Note
open-end
wrench
(arrow)
being
used
to
coun-
terhold
bolt
.

5
.
Loosen
threaded
clamping
sleeve
on
driveshaft
a
few
tucos
.
See
Fig
.
4
.

DRIVESHAFT
SERVICE

Fig
.
4
.



Threaded
clamping
sleeve
nut
being
loosened
.

0012037

6
.
Support
driveshaft
andremove
center
support
bearing

mounting
bolts
.

7
.
Remove
driveshaft
but
do
not
separate
two
halves
.
Pull

down
on
center
of
driveshaft
to
facilitate
removal
.

2
.
Remove
exhaust
heat
shield
and
heat
shieldcross-

member
.



NOTE-

If
driveshaft
halves
were
separate
and
not
match-

3
.
Matchmark
front
and
rear
driveshaft
connections
at



marked,
assemble
driveshaft
as
shown
in
drawing
.
If
a

transmissíon
and
final
drive
.



vibration
occurs,
disassemble
driveshaftand
rotate
one

section
180°
.
See
Fig
.
5
.

Driveshaft,
installing

Fig
.
5
.



Driveshaft
alignment
.
Centerlinesof
universal
joints
(arrows)

must
be
parallel
or
at
90°
to
each
other

1
.
Align
driveshaft
matchmarks
at
final
drive
and
then
at

transmission
flange
.
Start
attaching
nuts
.
Use
new
self-

locking
nuts
.

2
.
Position
center
support
bearing
and
start
attaching

nuts
.
Use
new
self-locking
nuts
.

3
.
Tighten
flangenuts
while
preventing
bolts
from
twisting

in
coupling
.
Tighten
final
drive
flange
first,
then
tighten

coupling
at
transmission
.

4
.
Preload
center
support
bearing
by
pushing
bearing
for-
ward4-6
mm
(0
.16-0
.24
in
.)
from
center
.
See
Fig
.
6
.
Tighten
attaching
bolts
.

330-
1
0



REAR
SUSPENSION

Trailing
arm,
removing
and
installing

1
.
Raise
rear
end
of
car
and
remove
wheel
.

WARNING
-

Make
sure
that
the
car
is
firmly
supported
on
jack
standsdesigned
for
the
purpose
.
Place
the
jack
standsbeneatha
structural
chassis
point
.
Do
not
place
jack
stands
under
suspension
parts
.

2
.
Remove
drive
axle
as
described
earlier
.

3
.
Remove
brake
rotor
and
caliper
as
described
in
340

Brakes
.
Do
not
remove
brake
line
from
caliper
.
Hang

caliper
from
body
with
wire
.

4
.
Remove
parking
brakecable
frombrake
shoe
expand-

er
.
See
340
Brakes
.

5
.
Remove
rear
brake
line
bracket
from
trailing
arm
.
See

Fig
.
17
.

Fig
.
17
.
Brake
line
bracket
bolts
on
trailing
arm
(arrow)
.

WARNING
-

It
is
recommended
that
a
restraining
chain
be
in-
stalled
between
the
bottom
coil
of
the
coil
spring
and
the
upper
control
arm
to
retainthe
spring
in
case
of
accidentalrelease
.
Personal
injury
can
re-sult
if
the
compressed
coil
spring
is
not
released
slow1y
and
carefully
.

REAR
SUSPENSION
ARMS

6
.
Support
trailing
arm
from
below
with
a
transmission
jackorequivalent
.

7
.
Remove
shock
absorber
to
trailing
arm
bolt
.
See
Fig
.
18
.
Slowly
lower
suspension
until
coil
spring
can
be
safely
removed
.

0013220

Fig
.
18
.
Support
trailing
arm
before
removing
lower
shock
bolt
(ar-

row)
.

8
.
Unbolt
upper
and
lower
control
arms
from
trailing
arm,

as
described
later
.

9
.
Remove
ABS
wheel
speed
sensor
from
rear
wheel

bearing
housing
.
Unclip
sensor
wiríng
from
trailing
arm
.

If
removing
right
trailing
arm,
separate
brake
pad
wear

sensor
connector
.
See
Fig
.
19
.

0012104

Fig
.
19
.
Brake
pad
wear
sensor
and
ABS
wheel
speed
sensor
con-
nectors
(arrow)
.

10
.
Remove
three
bolts
holding
trailing
arm
front
bracket
to
body
.
See
Fig
.
20
.
Remove
trailing
arm
.

330-
1
2



REAR
SUSPENSION

Upper
control
arm,

removing
and
installing

1.
Raise
rear
end
of
car
and
remove
wheel
.

WARNING
-

Make
sure
that
the
car
is
firmly
supportedon
jack

stands
designed
for
the
purpose
.
Place
the
jack

stands
beneatha
structural
chassis
point
.
Do
not

place
jack
stands
under
suspension
parts
.

2
.
Remove
drive
axle
as
described
earlier
.

3
.
Remove
stabilizer
bar
link
fromupper
control
arm
.

4
.
Support
trailing
arm
from
below
with
a
transmission

jackorequivalent
.

WARNING
-

It
is
recommended
that
a
retaining
chain
be
in-

stalled
between
the
bottom
coil
of
the
coil
spring

and
the
upper
control
arm
to
retain
thespring
in

case
of
accidental
release
.
Personal
injury
can
re-

sult
if
the
compressed
coil
spring
ís
not
released
slowly
and
carefully
.

5
.
Remove
lower
shock
absorber
bolt
.
Refer
to
Fig
.
18
.

Slowly
lower
trailing
arm
until
coil
spring
is
fully
re-

leased
.
Remove
restraining
chain
and
remove
spring
.

7
.
Installation
is
reverse
of
removal
.

"
Always
use
new
self-locking
nuts
.

"
Have
car
professionally
aligned
when
job
is
complete
.

"
Insta¡¡
drive
axle
as
described
earlier
.

Tightening
Torques

"
Drive
axleto
final
drive
flange

M8
Torx
bolt
..........
..
.
..
....
64
Nm
(47
ft-Ib)

M10
Torx
bolt
.........
..
..
.
...
100
Nm
(74
ft-Ib)

"
Shock
absorber
to
trailing
arm
..
..
..
77
Nm
(57
ft-Ib)

"
Upper
control
arm

to
final
drive
carrier
(M12
bolt)
...
..
.
77
Nm
(57
ft-Ib)

"
Upper
control
arm

to
trailing
arm
(M12
bolt)
.........



110
Nm
(81
ft-Ib)

Lower
control
arm,

1
.
Raise
rear
end
of
car
and
support
it
securely
on
jack-

stands
.
Remove
rear
wheel
.

2
.
Remove
both
lower
control
arm
mounting
bolts
.

FINAL
DRIVE
CARRIER

3
.
Use
a
soft
hammer
to
tap
control
arm
out
of
its
mount-

ing
points
.

4
.
Installation
is
reverse
of
removal
.

NOTE-

Use
a
new
bolt
and
washer
assembly
at
the
final
drive

carrier
mountíng
point
forthe
control
arm
.

Tightening
Torque

"
Lower
control
arm

to
final
drive
carrier
(M12
bolt)
......
77
Nm
(57
ft-Ib)

"
Lower
control
arm

to
trailing
arm
(M12
bolt)
....
..
.
..
110
Nm
(81
ft-Ib)

FINAL
DRIVE
CARRIER

Final
drive
carrier,

removing
and
installing

1
.
Raise
rear
end
of
car
and
support
it
securely
on
jack

stands
.
Remove
rear
wheels
.

2
.
Remove
driveshaft
.
See
260
Driveshaft
.

3
.
Remove
both
drive
axles
as
described
earlier
.

6
.
Remove
both
upper
control
arm
mounting
bolts
.
Re-

move
control
arm
.



4
.
Disconnect
stabilizer
bar
from
upper
control
arms
.
Re-

move
stabilizer
bar
mounts
.

5
.
Disconnect
speedometer
harness
connector
on
final

drive
(where
applicable)
.

6
.
Remove
rear
section
of
exhaust
system
.
See
180
Ex-

haust
System
.

NOTE-

It
may
be
easier
to
remove
complete
exhaust
asonepiece
.
See
180
Exhaust
System
.

7
.
Remove
upper
and
lower
control
arms
as
described

earlier
.

8
.
Support
final
drive
carrierwith
transmissíon
jack
.
Re-

move
mounting
bolts
and
nuts
at
final
drive
carrier

bushing
mounts
.
See
Fig
.
22
.

9
.
Slowly
lower
final
drive
and
final
drive
carrier,
detaching

removing
and
installing



wire
harness
and
connectors
as
necessary
.

10
.
Finaldrive
may
now
be
unbolted
from
final
drive
carrier
.

Final
driveinputshaft
oil
sea¡,
replacing

1
.
Raise
car
and
support
safely
.

2
.
Drain
final
drive
oil
as
described
earlier
.

3
.
Remove
driveshaft
from
final
drive
inputshaft
flange
.

See
260
Driveshaft
.

4
.
Make
matching
marks
on
input
shaft
and
inputshaft
collar
nut
.
See
Fig
.
4
.

Fig
.
4
.



Make
matching
marks
on
input
shaft
collar
nut
and
flange
.

5
.
Pry
lockplate
from
nut
.
Hold
input
flange
andremove

collar
nut
.
If
necessary,
usea
pullerto
remove
input

flange
.

6
.
Remove
final
drive
front
dust
cover
.

8
.
Install
new
final
drivefront
dust
cover
.

9
.
Lightly
lubricate
inputshaft
and
press
input
flange
back

on
.
Insta¡¡
collar
nut
and
slowly
tighten
until
matching

marks
line
up,
coming
as
close
aspossible
to
specified

torque
.

Tightening
Torques

"
Final
driveinputshaft
flange
to
pinion

with
4
bolt
side
covers
.



.........
175
Nm
(129
ft-Ib)

(or
until
match
marks
line
up)

"
Finaldriveinputshaft
flange
to
pinion
with
6
bolt
side
covers
...........
185
Nm
(137
ft-Ib)

(or
until
match
marks
line
up)

CA
UTION-

If
the
input
flange
nuttorque
is
exceeded,
or
the
nut
is
tightened
past
the
marks,
the
crushable
col-
lar
sleeve
behind
theflange
will
need
to
be
re-
placed
.
This
operation
requires
disassembly
of
the
final
drive
unit
.

10
.
Install
a
new
lockplate
and
refill
final
drive
with
lubri-

cant
.

11
.
Remaining
assembly
is
reverse
of
disassembly
.

Tightening
Torques

"
Driveshaftto
final
dríve
flange
...
See260
Driveshaft

"
Flex-disc
to
driveshaft
or
transmission
flange
...........
See260
Driveshaft

"
Finaldrivedrain
and
fill
plugs
...
.
..
.
70
Nm
(52
ft-Ib)

Final
drive
unit,

removing
and
installing

FINAL
DRIVE



331-
3

1
.
Raise
rear
end
of
car
and
support
it
securely
on
jack
stands
.
Remove
rear
wheels
.

2
.
Remove
driveshaft
from
final
drive
input
flange
.
See
7
.
Pry
faulty
sea¡
from
its
recess
using
a
hooked
sea¡
re-



260
Driveshaft
.
moval
toolor
a
large
screwdriver
.
Dip
new
sea¡
in
final

drive
lubricant
and
drive
it
into
position
.



3
.
Remove
both
drive
axles
from
final
drive
unit
.
Suspend

axle
using
stiff
wire
.
See
330
Rear
Suspension
.

CAUTION
-

ee
careful
not
to
mar
the
housing
when
removing



4
.
Disconnect
stabilizer
bar
from
upper
control
arms
.
Re-

the
seas
.



move
left
and
rightstabilizer
bar
mounts
.

5
.
Disconnect
speedometer
harness
connector
on
final

drive
(where
applicable)
.

6
.
Support
final
drive
with
transmission
jack
.
Remove

mounting
bolts
atfront
and
rear
.
See
Fig
.
5
.

7
.
Slowly
lower
final
drive
unit
and
remove
towards
rear
.

FINAL
DRIVE
SERVICE

Brake
rotor,
removing
and
installing

Brake
rotors
shouldalways
be
replaced
in
pairs
.

Fig
.
9
.



Brake
rotor
mounting
screw
(arrow)
.

3
.
Inspect
rotor
for
excessive
grooving,
cracks,
and
warp-

ing
.
Check
rotor
thickness
.
See
Table
b
.

4
.
Installation
is
reverse
of
removal
.

"
Clean
rotor
with
brakecleaner
before
installing
.

"
If
brake
fluid
hose
veas
removed
or
loosened,
brake

systemmustbe
bled
as
described
aboveunder

Bleeding
Brakes
.

BRAKES
340-
7

5
.
Once
brake
assembly
is
instalind,
depress
brakepedal

several
times
to
adjust
caliper
and
pads
.

"
Pedal
should
feel
firm
and
be
at
proper
height
.

"
Check
fluid
leve¡
.
Top
up
if
necessary
.

NOTE-

M3
models
use
directional
brake
rotors
and
mustbe
in-



NOTE-

stalled
on
the
proper
side
.
Part
numbes
are
cast
finto



When
installing
new
rear
brake
rotors,
the
parking

therotors
.
A
part
that
ends
in
an
odd
number
is
a
left



brakeshouldbe
adjusted
.
See
Parking
Brake
.

rotor
.
One
that
ends
in
an
even
number
is
a
right
rotor
.

1.
Remove
caliper
as
described-above
and
hang
from



Tightening
Torques
chassis
using
stiff
wire
.



"
Brake
rotor
to
wheel
hub
..........
16
Nm
(12
ft-Ib)

"
Front
brake
caliper
to
steering
arm
...
110
Nm
(81
ft-Ib)

NOTE-



"
Rear
brake
caliper
to
traíling
arm
....
67
Nm
(50
ft-Ib)

Do
notloosen
caliper
brake
hose
.



"
Road
wheel
to
hub



...
..
.
100
±
10
Nm
(74
t
7
ft-Ib)

2
.
Remove
mountingscrew
holding
rotor
to
wheel
hub
.



,

See
Fig
.
9
.



Table
b
.
Brake
Rotor
Reconditioning
Specificati*M`

Front
Rear

Vented
rotor
wear
limit
(min
.
thickness)



20
.4
mm
(0
.803
in.)

Solid
rotor
wear
limit
(min
.
thickness)



8
.4
mm
(0.331
in
.)

M3
models
wear
limit
(min
.
thickness)



26
.4mm
(0
.977
in
.)



18
.4
mm
(0
.723
in
.)

Axial
runout
(max
.)
rotor
removed



0
.05
mm
(0
.002
in
.)



0
.05
mm
(0
.002
in
.)
rotor
installed



0
.20
mm
(0
.008
in
.)



0
.20
mm
(0
.008
in
.)

CAUTION-

M3
brake
rotors
must
not
be
machined
.

MASTER
CYLINDER

The
brake
master
cylinder
is
mounted
to
the
front
of
the
vac-

uum
booster
on
the
driver
side
bulkhead
.

Master
cylinder,
removing
and
installing

1
.
Using
a
clean
syringe,
empty
brake
fluid
reservoir
.

WARNING
-

Brake
fluid
is
highly
corrosive
and
dangerous
to
the

environment
.
Dispose
of
it
properly
.

NOTE-

On
original
equipment
rotors,
the
mínimum
allowable



2
.
Disconnect
brake
fluid
leve¡
sender
connector
from
fluid

thickness
is
stamped
on
the
rotor
hub
.
Measure
the
rotor



reservoi
r
cap
.

brakingsurface
with
a
micrometer
at
eight
to
ten
different

points
and
use
the
smallest
measurement
recorded
.



3
.
Disconnect
brake
fluid
lines
frommaster
cylinder
.
See

Fig
.
10
.
Disconnect
hydraulic
clutch
system
supply
line
.

4
.
Unscrew
mounting
nuts
and
remove
master
cylinder

from
brake
booster
.

5
.
Make
sure
all
nuts,
fluid
couplings,
thread
bores,
and

mating
surfaces
are
clean
.

MASTER
CYLINDER

6
.
Disconnect
ABS
electrical
connectors
.
Label
and
then

disconnect
brake
lines
from
hydraulic
brake
unit
.
Plug

openíngs
.
See
Fig
.
12
.

~
~
A
1/
B
'1v
C
~
F

lu
11
-ri
J
.

0013244
A
.
Right
front



F



Front
from
master
cylinder
B
.
Leftfront



R
.
Rear
from
master
cylinder
C
.
Rear

Fig
.
12
.
Brake
fluid
linesat
ABS
hydraulic
unit
.

WARNING
-

"
On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
required
to
properly
bleed
the
Antilock
Brake
System
(ABS)
.
Removal
of
the
ABS
hydraulic
unit
is
not
recommended
un-
less
this
equipment
is
available
.
For
safetyrea-
sons,
the
brake
system
on
cars
with
ABS
must

not
be
bled
using
the
procedures
described
inthis
repair
group
.

"
Do
not
mix
up
the
fluid
fines
at
the
ABS
hydraulic
unit
Label
all
connections
before
disconnecting
.

7
.
Remove
ABS
hydraulic
unit
from
engine
compartment
.

8
.
Working
inside
car,
remove
panel(s)
frombeneath

steering
column
to
access
pedal
assembly
.
See513
In-

terior
Trim
.

12
.
Make
sure
al¡
nuts,
fluid
couplings,
thread
bores
and

mating
surfaces
are
clean
.

BRAKES
340-
9

0011261

Fig
.
13
.
Brake
pedal
clevispin
and
retaining
clip
(A)
.
Brake
booster
mounting
nuts
shown
at
arrows
.

13
.
If
necessary,
mount
master
cylinder
to
vacuum
booster

using
a
new
O-ríng
and
newself-locking
nuts
.

CAUTION-

Do
not
over-torque
the
master
cylinder
mounting
bolts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

14
.
Installation
is
reverse
of
Rmoval
.

"
Bleed
brakes
as
described
earlier
.

"
Check
and,
if
necessary,
adjust
brake
light
switch

above
brake
pedal
.

Tightening
Torques

"
Brakemaster
cylinder
to

brake
booster
...........
.
..
..
...
26
Nm
(18
ft-Ib)

"
Brake
booster
to
bulkhead
.
.
..
..
...
22
Nm
(16
ft-Ib)

"
Brake
fluidline
to
master
cylinder
or

ABS
hydraulic
unit
.......
.
..
17-19
Nm
(13-14
ft-lb)
9
.
Remove
clip
and
clevis
pin
from
brake
booster
pushrod

and
disconnect
it
from
brakepedal
.
Remove
brake

booster
mounting
nuts
.
See
Fig
.
13
.
NOTE-

10
.
Working
in
engine
compartment,
remove
brake
booster



When
replacing
the
brake
booster
one-way
valve
or
together
with
master
cylinder
.



vacuum
hose,
install
the
valve
so
that
the
molded
arrow

is
pointing
toward
the
intake
manifold
.
Use
new
hose

11
.
If
booster
or
master
cylinder
O-ring
is
being
replaced,



clamps
.

disconnect
master
cylinder
from
brake
booster
.

BRAKE
BOOSTER

340-
1
2
BRAKES

ABS
is
self-tested
by
the
ABS
diagnostic
unit
each
time
the
car
is
started
.
Once
the
test
is
complete,
the
ABS
dashboard
light
tucos
off
.
If
the
light
remains
lit
or
comes
on
at
any
time
during
driving,
a
system
fault
has
occurred
and
ABS
is
elec-
tronically
disabled
.
The
conventional
braking
systemremains
fully
functioning
.

ABS
Inspection

A
visual
inspection
of
the
ABS
may
help
to
locate
system
faults
.
If
no
visual
faults
can
befound
and
the
ABS
light
re-
mains
on,
have
the
system
diagnosedbyan
authorized
BMW
dealer
.

Carefully
inspect
the
entire
ABS
wiring
harness,
particularly

the
pulse
sensorharnesses
and
connectors
near
each
wheel
.

Look
for
chafing
or
damage
due
to
incorrectly
routed
wires
.

Carefully
remove
the
wheelspeed
sensors
.
Clean
the
sen-



Fig
.
18
.
Front
ABS
pulse
sensor
mounting
bolt
(arrow)
.
sor
tips
.
Inspect
the
toothed
wheel
on
thewheel
hub
.
Check
for
missing,
clogged
or
corroded
teeth,
or
other
damage
that
could
alter
the
clearance
between
the
sensor
tip
and
the
toothed
wheel
.

NOTE-

If
a
toothed
ring
is
damaged,
the
entire
wheel
hub
mustbe
reptaced
.
See
310
Front
Suspension
or330
Rear
Suspension
.

ABS
wheel
speed
sensors,
replacing

1
.
Raise
applicable
end
of
car
.

WARNING
-

Make
sure
thecar
is
firmly
supportedon
jack
stands
designed
for
the
purpose
.
Place
the
jack
stands
be-
neath
a
structural
chassis
point
Do
not
place
jack
stands
under
suspension
parts
.

2
.
Unscrew
wheelspeed
sensor
mounting
bolt
.
Remove
sensor
from
its
housing
.
See
Fig
.
18
.
Remove
harnessfrom
retaining
mounts
.

3
.
Front
ABS
sensor
:
Working
in
front
wheel
housing,
dis-
connect
and
remove
sensor
.
See
Fig
.
19
.

4
.
Rear
ABS
sensor
:
Working
in
rear
wheel
housing,
dis-
connect
andremove
sensor
.

5
.
During
installation,
apply
thin
coat
of
Molykote
0
Long-
term
2
or
an
equivalent
grease
to
pulse
sensor
and
housing
.

ANTILOCK
BRAKE
SYSTEM
(ABS)

0012122
Fig
.
19
.
Front
ABS
wheel
speed
electrical
connector
(arrow)
in
wheel
well
.

6
.
Installation
is
reverse
of
removal
.

GENERAL

This
repair
group
covers
front
and
rear
door
repair
informa-
tion,
including
removal
and
installationof
the
interior
doorpan-
els
.

DOORS

WARNING
-

Late
M3
moddis
havealuminum
doors
.
Use
extra
care
in
handling
aluminum
parts
in
order
to
avoid
damage
from
gouging
or
corrosión
.

NOTE-

"
For
information
on
the
power
door
windows
and
door
glass
replacement,
sea512Door
Windows
.

"
Forinformation
on
the
power
door
locking
system,
see
515
Central
Locking
and
Anti-Theft
.

WARNING
-

Some
1997
and
all
1998
cars
are
fitted
with
side-im-
pact
airbags
in
the
front
doors
.
When
servicing
doors
on
cars
with
front
side-impact
airbags,
always
dis-
connect
the
negative
(-)
battery
terminal
.
See
721
Airbag
System
(SRS)
for
cautions
and
procedures
relating
to
the
airbag
system
.

Front
orrear
door,
removing
and
installing

1
.
If
workingon
front
door
with
side-impact
airbag,
discon-

nect
negative
(-)
battery
cable
.

CAUTION
-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vüi
.

2
.
Unbolt
main
harness
connector
at
door
pillar
and
sep-
arate
connector
.
See
Fig
.
1
.

411
Doors

GENERAL
.............
.
.
.
.
.
.
.
.
.
.
.
.
.
..
411-1



DOOR
PANELS
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
.
.
...
.
.
411-4

Front
door
trim
panel,
removing
and
installing
.411-4
DOORS
..
.
.
.
.
.
.
.
.
.
...
.
.......
.
....
.
.
.
411-1



Rear
door
trim
panel,
removing
and
installing
.411-5
Front
or
reardoor,
removing
and
installing
..
.
411-1



Rear
side
trim
panel,
removing
and
installing
Door
check,
replacing
.
.
.
.
.
.
.
.
.
.
.
.
.......
411-3



(coupemodel)
.
.
.
.
.
.
....
.
.............
411-6

Door
Adjustment
.......
.
.
.
.
.
.
.
.
.
.
.
.....
411-3



Rear
side
trim
panel,
removing
and
installing
(convertible
models)
.
...
.
.
.
.
.
.
.
.
.
.
.
...
.
411-6

DOORS
411-1

Fig
.
1
.



Door
harness
connector
being
removed
fromdoor
pillar
.
Re-
move
mountingscrews
atA,
then
separate
connector
by
pulling
upon
harness
lock(top
arrow)
.

3
.
Withdoor
fully
open,
remove
pin
bolts
from
top
and
bot-
tom
door
hinges
.
See
Fig
.
2
.

0011650

Fig
.
2
.



Door
hinge
pin
bolt
(arrow)
.
Top
hinge
shown
.
Also
remove
pin
bolt
from
lowerhinge
.

DOORS

Door
Hinge
Adjustment

If
the
installed
door
is
uneven
or
out
of
parallel,
shims
can
be
used
to
correct
its
position
.
The
shims
are
placedbehind
the
hinge
plate
and
are
available
in
two
different
thicknesses
(0
.5
mm
and
1
.0
mm)
.
See
Fig
.
4
.

Tightening
Torque

"
Door
hinge
to
door
.............
..
21
Nm
(15
.5
ft-I
b)
"
Door
striker
to
door
...........
...
25
Nm
(18
ft-Ib)

DOOR
PANELS

0
l
o
0013102

Fig
.
4
.



Door
hinge
and
door
check
components
.
Front
and
rear
doors
are
similar
.

WARNING
-

Some
1997
and
all
1998
cars
are
fitted
with
side-im-
pact
airbags
in
the
front
doors
.
When
servicing
doors
on
cars
with
front
side-impact
airbags,
always
dis-
connect
the
negative
()
battery
terminal
.
See
721
Airbag
System
(SRS)
for
cautions
and
procedures
relating
to
the
airbag
system
.

Front
door
trimpanel,
removing
and
in-

stalling

1
.
On
cars
with
side-impact
airbags,
disconnect
negative

(-)
battery
cable
.

CAUTION
-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.

Fig
.
5
.



Pry
outside
mirror
switch
from
door
armrest
.

3
.
Unscrew
door
locking
knob
.

Fig
.
6
.



Pry
off
plugs
(arrows)
and
remove
screws
.

DOORS
411-
3

2
.
Carefully
pry
out
mirror
adjustment
switch
and
discon-
nect
harness
connector
from
switch
.
Fig
.
5
.

5
.
Unclip
door
panel
from
door
perimeter
.
See
Fig
.
7
.

0013168

4
.
Pry
off
trim
cover
for
insíde
door
handle
.
Pry
off
con-
cealing
plugs
from
armrest
.
Remove
door
panel
retain-
ing
screws
.
See
Fig
.
6
.

UU13169

DOOR
PANELS

411-
4
DOORS

6
.
Disconnect
radio
speaker
harness
connector
.

Fig
.
7
.



Door
panel
being
unclipped
from
door
.
Pull
panel
retaining

clips
off
one
at
a
time
.

7
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Replace
any
damaged
plastic
parts
orclips
.

"
Renew
vapor
barrier
ifit
is
damaged
.

"
Use
new
mounting
bolts
when
reinstalling
the
side-im-

pactairbag
to
the
door
(where
applicable)
.

"
When
installing
door
panel,
align
metal
retainers
on

window
sill
with
openingsontop
of
door
panel
.
See

Fig
.
8
.

"
Check
door-lock
mechanism
and
window
for
ease
of

movement
.

"
If
battery
was
disconnected,
re-initialize
window
regu-

lator
motors
as
described
in
512
Door
Windows
.

373

Fig
.
8
.



Metal
retainers
at
base
of
window
should
be
in
position
to
mate
with
openings
in
door
trim
panel
.

DOOR
PANELS

Reardoor
trimpanel,

removing
and
installing

1
.
Open
door
and
pry
out
power
window
switch
.
Discon-

nect
harness
connector
.

2
.
Remove
ash
tray
.

3
.
Pry
off
trim
cover
from
inside
door
handle
.

4
.
Pry
off
concealing
plugs
from
armrest
.
Remove
door

panel
retaining
screws
.
See
Fig
.
9
.

Fig
.
9
.



Pry
off
plugs
(arrows)
andremove
screws
.

5
.
Unscrew
door
locking
knob
.

6
.
Unclip
panel
from
door
perimeter,
starting
at
thetop
of

the
door
.

7
.
Installation
is
reverse
of
removal
.

"
Replace
any
damaged
plastic
parts
or
clips
.

"
Renew
vapor
barrier
ifit
is
damaged
.

"
Align
metal
retainers
on
window
sill
with
openings
in

trim
panel
.
Refer
to
Fig
.
8
.

"
Check
door-lock
mechanism
and
window
for
ease
of

movement
.

Rear
side
trim
panel,
removing
and
install-

ing
(coupe
models)

1
.
Remove
rear
seat
cushion
.
Remove
rear
backrest
side

section
.
See
520
Seats
.

2
.
Pull
off
edge
trimat
bottom
of
rear
side
window
.
See

Fig
.
10
.

3
.
Gently
unclip
trim
panel
andremove
.

4
.
Installation
is
reverse
of
removal
.

"
Replace
any
damaged
plastic
parts
or
clips
.