Removal, installation and adjustment of side doors (Opel Astra H)

Removal and installation

1. Disconnect the cable from the negative terminal of the battery (see Chapter 5).

2. Open the door and tape the edges of the door.

3. Unscrew the mounting bolt and disconnect the limiter (see accompanying illustration) door travel from the body pillar.



4. To disconnect the electrical wiring connector (see illustration 17.3) on the front door, pull back the red locking bar while turning the connector counterclockwise, and on the rear door connector, press in the blue locking bar.

5. Remove the rubber caps from the door hinges, use an assistant to knock out the hinge pins and remove the door.

Note: The hinge pins should protrude from the end where the cap was placed.

6. Installation is carried out in the reverse order of removal. Before installation, lubricate the door hinge pins with waterproof grease. After installing the door on the hinges, make the appropriate adjustments (see below). Tighten the door hinge mounting bolts to the required force.

Adjustment

7. Remove the lock bracket (see illustration 17.1b to Chapter 1).



8. Alignment of the door in the body opening is performed by bending the door hinges. This operation requires a certain amount of experience - if you are not confident in your abilities, contact a service station. There is a special tool for bending hinges on sale, for example, HAZET 1931 and HAZET 1973-1.

9. Close the door and check the gap between the adjacent body elements (see Specifications). The tailgate is adjusted correctly if, in the closed position, there is a uniform gap around the entire perimeter and the door is flush with the surrounding body surfaces

10. Adjust the door if necessary. The front edge of the rear door may be no more than 1 mm deeper than the rear edge of the front door.

11. Replace the side door lock bracket and tighten its mounting bolts by hand. Carefully close the side door, this will move the lock bracket into the desired position. Open the door and tighten the bracket mounting bolts.

12. Close and open the door several times, check its position and ease of closing/opening, repeat the adjustment if necessary and eliminate any damage to the coating that has occurred due to bending of the hinges.