Door and Headlight removal
Discussion
Since there has been interest in many copies of the instructions:
Remove the interior door panel. On an SE unscrew the interior door handle and trim ring. Not sure on an S4 door panel. If taking apart the door you must remove the screen frame.
Disconnect the electrical harness and feed out of the door shell.
Remove the upper and lower hinge to body fixings. Keep in mind the correct shim plates and their locations to reinstall later with the correct shims.
Also after removing the window frame, window mechinism, latch mechimism, and door shell fixings. You can slide the door off the beam and leave the beam attached by removing 2 M8 bolts near the door latch and 2 M6 by towards the front of the door.
Pod removal:
Take off the front bonnet to make it easier to work on.
Remove lights in back of the lights you will see the fastners on each side. Also undo the pod from the acutators. The fastners towards the center of the car is threaded into the bonnet hinge bar. The outside fastners threaded to the body.
Calvin
Calvin
Remove the interior door panel. On an SE unscrew the interior door handle and trim ring. Not sure on an S4 door panel. If taking apart the door you must remove the screen frame.
Disconnect the electrical harness and feed out of the door shell.
Remove the upper and lower hinge to body fixings. Keep in mind the correct shim plates and their locations to reinstall later with the correct shims.
Also after removing the window frame, window mechinism, latch mechimism, and door shell fixings. You can slide the door off the beam and leave the beam attached by removing 2 M8 bolts near the door latch and 2 M6 by towards the front of the door.
Pod removal:
Take off the front bonnet to make it easier to work on.
Remove lights in back of the lights you will see the fastners on each side. Also undo the pod from the acutators. The fastners towards the center of the car is threaded into the bonnet hinge bar. The outside fastners threaded to the body.
Calvin
Calvin
The door has never been a favorite to take off.
As you can see there are two ways to take off he door.
Door and beam as an assembly or the door and leave the beam on. The choice is yours.
It is a bitch when the shim plates falls of before one notes the number and position of the shims.
Even the light pods has spacer washer to align the body to pod gaps. I am a stickler for such things and they bother me a lot when the body lines do not match up.
When looking at a car, my car in particular I look at things that others overlook. In fact I am critical at my paint job. When I was checking out my car prior to purchase the PO thought I was strange. Putting my eye on the tail lights and looking down the sight line of the body to the front bumper. running my finger down the gaps in the body to measure uniformity.
I adjusted just about every gap in the doors, light pods, centered the tail pipe in rear valence, the glove box, the front and rear hatch. I tightened every bolt and screw in the car including the instrument in the pod and the pod itself. There are no squeaks or rattles in my car.
I guess if you heard what I went through to get my modest 90 SE and the hobby aspect of it you would know why I am so rabid about it. I still wonder if I should go V8/S4s. Ed Gomes has been trying to get me over to the V8's, so I can devle in to the workings of the Later model Esprit's.
Calvin
As you can see there are two ways to take off he door.
Door and beam as an assembly or the door and leave the beam on. The choice is yours.
It is a bitch when the shim plates falls of before one notes the number and position of the shims.
Even the light pods has spacer washer to align the body to pod gaps. I am a stickler for such things and they bother me a lot when the body lines do not match up.
When looking at a car, my car in particular I look at things that others overlook. In fact I am critical at my paint job. When I was checking out my car prior to purchase the PO thought I was strange. Putting my eye on the tail lights and looking down the sight line of the body to the front bumper. running my finger down the gaps in the body to measure uniformity.
I adjusted just about every gap in the doors, light pods, centered the tail pipe in rear valence, the glove box, the front and rear hatch. I tightened every bolt and screw in the car including the instrument in the pod and the pod itself. There are no squeaks or rattles in my car.
I guess if you heard what I went through to get my modest 90 SE and the hobby aspect of it you would know why I am so rabid about it. I still wonder if I should go V8/S4s. Ed Gomes has been trying to get me over to the V8's, so I can devle in to the workings of the Later model Esprit's.
Calvin
The head lights are a peice of cake! Also a nice time to take them out and polish the outside edges with some metal polish to get it looking like new although you wont see much of it when the black plastic shroud is back in place.
Just like Calvin said just some retaining screws. I beleive a big flat head will do the job. Good luck!
Just like Calvin said just some retaining screws. I beleive a big flat head will do the job. Good luck!
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