Replacement of door hinge

Due to a design related defect, the upper door hinges will start cracking when opening the door. This will be noticed only when the exterior temperature is warm. If cold, this cracking cannot be heard. The cause of this has not been clarified. However, it is clear that the locking mechanism in the hinge, responsible of holding the door in certain positions, is the source of the noise.

A short term remedy is to drill the hinge sleeve and apply lubricant through the hole. However, this prevents the cracking only for a few days/weeks. The only long term solution is to replace the affected door hinge, as described below.

These instructions are applicable to all variants of the MK4.

  • Parts:
    • New or used door hinge (:!: an used door hinge not installed in a car cannot be verified not to have the problem. Therefore, it is recommended to install it and test ahead, in warm wheather, over 20°C)
  • Tools and other aids:
    • Size 10 wrench or socket
    • Size 13 wrench or socket
    • Flat head screwdriver
    • A second person to hold the door while disassembling/assembling or a car jack if working alone

The process described here is an example on the front passenger door, but in principle is the same for every other door.

Step 1) removing the door

First, completely lower the window, to provide better holding options. Then unplug the door wiring loom. To do this, with the door open, pull out the connector and rubber grommet from the A pillar:

Then, press the retaining tabs of the connector, and pull out both body side connectors in sequence:

Support the door with the help of a second person or a car jack:

Using a 13 size wrench or socket, unscrew the bolts from the upper and lower door hinges:

Lift the door and put it away:

Step 2) remove defective door hinge

The upper door hinge is comprised of two parts: one bracket fixed to the vehicle's body and the other one the hinge itself. Both are connected by a size 10 bolt from below. Unscrew this bolt with a wrench or socket and remove it. Pay attention: this is a LEFT THREADED bolt, so unscrew in the opposite direction than normally:

Step 3) install the new door hinge

Hint: door hinges are painted during production only after being installed, so it is likely that the replacement won't be completely painted. Now it would be a good moment to have the whole area cleaned and repainted if necessary.

The only part required from the new hinge will be the upper part. As done before when removing the defective part, simply unscrew the 10 mm bolt, place the new part on the holder still fixed to the vehicle's body and screw the 10 mm bolt back to fix both parts together.

Step 4) reinstall the door

Bring the door back into position with the help of the second person or the car jack and bolt it to the hinge with the screws. The torque to tighten the upper hinge screws shall be 35 Nm, whereas those in the lower hinge shall be tighten to 47 Nm.

Then, connect the door wiring loom and push it back into the vehicle's body cavity.

Step 5) door alignment

Normally, the door will not be as perfectly aligned as it was before. To adjust, loosen the screws only of the door side to adjust in height, gap and alignment. To prevent damage to the paintwork, always pay attention when closing the door during tests!

Adjustments are done as follows:

  1. Place a car jack (with a piece of cloth to prevent paintwork damage) under the door, around the middle of the door but closer to the hinges.
  2. Adjust door height: sitting in the passenger's seat, lightly untighten lower and upper door hinges bolt and using the jack, lower or raise the door to its desired position, then fasten the door hinge screws (paying attention to the tightening torque). The best reference is to use body line spanning from the side turning lights, along the doors and to the rear of the car.
  3. Adjust door alignment (outer edge matching body): with the door open, support it using a car jack to prevent it from falling. The loosen the upper door hinge screws, door side. By pulling the upper part in the direction of travel, the door will be further out when closed, and viceversa, by pulling against the direction of travel. The tighten the upper door hinge screws, and repeat the same procedure for the lower hinge.

Each adjustment affects the other, therefore several trials will be necessary until the adjustment is correct again.

  • en/artikel/tueren/tuerscharnier_auswechseln.txt
  • Last modified: Mon. 11.03.2019 22:46
  • by jphid