Mercedes W203 Door Panel Removal
Karmen Mcarthun
It can take a tremendous amount of abuse and sooner or later something will fail. If you need to service your doors mechanicals or want to freshen up the appearance with new trim you will need to remove the door panel.
This article will show you how to remove your front door panels. It is not a difficult job, but door panels can be very expensive so take your time and double check things. Also, if you are going to be working on your own car, it is a good idea to purchase a set of trim removal tools. They are a set of hard yet flexible plastic tools of different shapes and sizes that are used in removing trim pieces. They work a lot better than a flat head screwdriver and there is nothing worse than ruining a "do-it-yourself" project by scratching up your car or damaging expensive interior pieces. Pelican sells a full line of these tool sets for under $20.
Before you begin removing the door panel, you need to disconnect the battery and let the car sit for half an hour. You are going to be working around the air bag and you want to make sure there is no electricity flowing in the car and that there has been time for the residual power to drain. You should also park the car on as level ground as possible. Nothing is more frustrating than working on the door while it is trying to swing open or closed.
First remove the plastic lock along the upper ledge. It unscrews counter clock wise. The door panel is only held on by three attached pieces of hardware. The first is the door lock trim piece. Remove this piece by unscrewing the single T20 Torx head screw and pulling the trim piece straight back.
Second is the door pull handle. Use your trim removal tool and gently pry the cover off the pull handle. With the handle off use your T27 Torx and remove the 2 screws inside the handle securing it to the door.
You will need to remove the small triangular shaped piece at the top front of the door that holds the speaker. Insert your trim removal tool at the top by the glass and pop it out. It will slide forward as you remove it. Disconnect the wires from the speaker.
There are seven clips that hold the panel to the sides and bottom of the door. Use your trim removal tool and gently pry the panel away from the door. If your door panel has never been removed it may take a little force.
This article will show you how to remove your rear door panels. It is not a difficult job, but door panels can be very expensive so take your time and double check things. Also, if you are going to be working on your own car, it is a good idea to purchase a set of trim removal tools. They are a set of hard yet flexible plastic tools of different shapes and sizes that are used in removing trim pieces. They work a lot better than a flat head screwdriver and there is nothing worse than ruining a "do-it-yourself" project by scratching up your car or damaging expensive interior pieces. Pelican sells a full line of these tool sets for under $20.
There are eight clips that hold the panel to the sides and bottom of the door. Use your trim removal tool and gently pry the panel away from the door. If your door panel has never been removed it may take a little force.
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The tool you absolutely need is simply just a Torx driver with T30 Torx bit. The rest are really good to have: trim removal pry, grip work gloves, addition narrow tip flat heas screw driver to depress the connector's release tabs.
1. Using the T30 torx bit driver, unscrew the torx headed screws from the 2 locations circled in red. A magnetized torx bit will be better to make sure your unscrewed screws don't drop into some of the narrow gaps in the door frame.
2. Next, use the interior trim pry to pull the interior door panel from the metal door frame. The locations of the various panel studs are shown in the picture as illustrated. So pry at the right location. Be careful of the door lock stub once the panel is pulled free from the frame. Make sure you don't lose any of the panel studs.
The rear right door check snapped off close to the hinge on my 1983 300td and although it is not the biggest deal i was hopping I could replace it myself and not have to take it to someone even though its not a big deal you just need to be a little more careful closing that door I just like to have everything in perfect working order. I have read the door panel removal guide and i was wondering if anyone could give me a little more direction towards this specific problem. Also is it worth it to do it myself cause i worry that once i take the door off I'm opening myself up for more problems to arise?
The first step is to use a pair of needle nose pliers and/or a screw driver to remove the C-clip that holds the pin in place where the strap connects to the body of the car. With the c-clip out, you can then use a small punch tool to tap the pin out towards the top of the door. This will let you remove the throw away the broken piece of the strap.
With the door panel off you can now remove the three bolts that hold the rest of the door check part. There should be one bolt at the end of the door check, furthest from the strap, on the part of the door usually covered by the panel. Then there will be two more bolts on the inside edge of the door, near where the strap protrudes out.
Also, note the position/location of the small white plastic spacer at the door jamb end of the check strap before removing the clip and pin. Make sure it is saved and put back in the same place for the new door check.
NOT COVERED: This video does not cover the removal or repair of the window regulator. Please send related video for more on that topic. Vacuum door lock repair is not covered nor is removal or replacement of the outside door handle or door latch assembly. Front door panel removal is not covered in this video. Principles are similar but there are some differences due to the power seat switch.
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Important note: This video manual may or may not include all the information you will need to troubleshoot and/or repair your specific problem/s. Please read the full description carefully to determine if this video is applicable to your year and model and contains the information you are looking for. If not, please refer back to our "Solutions Finder" and enter your chassis number and the specific problem you are having to see if we offer a solution.
Malfunctioning and failed power window regulators (mechanisms) are so common on older Mercedes that Kent can almost guarantee if you own one and drive it regularly you will have to fix one at some point.
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