Blue 02

Here are the notes with photos included. 2002 Door Refresh Project.pdf

2002 Door Refresh Project This winter project on my 1973 2002 was to refresh the inner portion of the doors. This included new door cards, chrome trim piece on the outside top of the door, window felt, and vent window seal replacement. FAQ tips were a lot of assistance to me as I did this and thought my notes might be helpful to someone else in the future! I’ve attached the part list of part numbers and quantities I used on my driver and passenger doors. Some of what I did was trial & error like many others on this forum, but here is the order I did the project with some photos as well. 1. Remove door cards/panels (tips from FAQ post) a. unscrew armrest and remove b. unscrew window crank (screw under plastic trim) and remove c. unscrew door handle (pop plastic trim off to access) d. remove vent window knob (feel around back side of the knob with a small allen wrench until the short end of the wrench pops into a hole. Then push until the center cover pops off, revealing the mounting screw e. Unsnap the perimeter fasteners (front, rear and bottom edges) by gently pulling the door card toward you, or prying from behind with a plastic trim tool f. Push upward on the now freed door panel; it's fastened at the top with friction clips that can be pretty firm; you might have to tap on the panel's bottom edge with a rubber mallet. DO NOT pry on the aluminum strip atop the panel; you'll bend it and never get it straight again. 2. Remove the liner if there is one, clip receptors, and vacuum out the door 3. Next step was to install the rattle kit from Maximillian Imports 4. If doing the vent window gasket, you’ll need to remove the bolt holding the bottom of the wing window frame to remove the window. Go through the hole below the vent window on the inside of the door to remove a. Tape off chrome trim pieces to protect from possible scratches in the area (don’t ask me why I know to do this!) b. I drilled out the rivets holding the top of the vent window frame into the door frame. A 5/32” drill bit fit great c. Remove the old gasket d. Clean out the metal area where the new gasket will insert into and then apply some dish soap to assist in getting the new gasket in e. For me the two hardest portions to get in were the bottom and the long straight vertical portion of the frame. f. I used a plastic trim tool to get the seal in place g. Reinstall vent window, replace bolt holding bottom rod and install two rivets to hold top mounting piece in place i. I used 1/8” x ¼” long rivets. Personal choice on whether you use aluminum or stainless rivets 5. I lubricated the door locking mechanism with WD-40 Dry-Lube and all the window rollers and mechanisms with Wurth HHS-K 6. Next step I did was remove the chrome trim piece on the top outside of the door. a. I taped under the strip with to protect the paint when removing the strip as well as for when installing the new parts b. Using the BMW repair manual, they showed using a wood piece to hit the bottom of the strip and it worked well for removal 7. Next step was to replace the U-shaped felt in the window frame adjacent to the vent window. a. From FAQ, I followed these steps i. Rolled the window all the way down, pinched the old felt together at the top and pull the old felt out of the channel. There are little points that grab onto the felt when they're installed. Trimmed the new felt to size, rolled the window up a third of the way and started feeding the channel in as I rolled the window down. I didn't need any lube. A little tight to roll up at first but, loosens up and no more slop. ii. Be careful where you pull! There is a small plastic part at the top that inserts into vent window frame that is NLA – one window didn’t have one and I damaged the part on the other window! 8. Next step I did was to clean of the door where the new liner will adhere to and let it dry overnight and vacuumed the inside of the door again a. After it was dry and prior to applying a soap solution to aid in installing the liner, I sprayed two coats of Amsoil MP HD on the inside bottom of the door for some rust protection since I don’t plan to do this again in my lifetime! 9. Following the instructions for installing the door liners (purchased from fellow FAQer @alprada) I wet the surfaces the door liner would adhere to with a soapy solution and then applied the liner, put on some tape to hold in place, and let dry overnight a. Only area that didn’t have a cut out, was the door lock rod. I made a cut with scissors to allow the rod to fit through the liner b. The next day, I remove the tape holding the sides on. I did leave the tape on top to ensure I didn’t move the liner while installing the new door card c. Installed the 12 clip receptors. I didn’t know about these, but they were under the old door cards and are in place to help keep moisture from coming through onto the new door card 10. While the door liner was drying, I prepared the new door card for installation a. Inserted the 12 door clips b. Marked where the holes would be needed for the vent window knob, door handle, armrest screws, and window crank c. Assembled and attached the chrome trim piece with new felt cut to length with measurement from felt removed off the old door card 11. Prior to installing the door card, I installed the two end trim pieces on the door and the door lock knob 12. Installed the door card next by sliding it over the top of the door lock knob, aligning it with the door clip holes and the vent window rod, door handle, and window handle rods. a. I carefully enlarged the holes for the three “rods” – vent window/door handle/window handle with a razor blade and gently moved the white matting material aside to allow the door card to go over the rods i. With a towel and a rubber hammer, I then tapped the top of the door card in place to seat the clips ii. Following this, I pressed each green door clip into the receptors until I heard a “click” 13. Following this, I installed the outside chrome trim part on the door a. Aligned the part so the vent window frame was in the right location and used a towel and rubber mallet to tap the trim piece into place 14. Next step was to reinstall the vent window knob, the window handle, door handle, and armrest a. After this, I installed the new vent window knob cap and the covering piece for the door handle The end product looks good! 73 Inka Door Refresh FAQ.pdf

Thank you!

Hi I'm working to “refresh” my doors and am looking for some help on where to install part # 51 21 1 847 798. It is a rubber seal. Does it go on the outside of the door under the top chrome strip? Is orientation so it is on the paint side or inside the door frame? thanks for assistance!

Thanks for the replies - I'll try drilling out the rivets. Rich

Hello I've been reading posts on this topic and if possible I'd like to replace the vent window seal without removing the entire assembly to do it. Anyone have success removing the vent window with the assembly still mounted to the door? Read one post where they said they were able to "push" the vent window down enough to get the upper pin out. Thanks for your assistance!

Hi - working to install this kit on my 73. Any tips on where to start and did anyone find instructions? Thanks- Rich

I use Kummrow Automotive in Glendale, WI (just north of Milwaukee) for maintenance on my 73 2002s - one a base and one a Tii. You could give Pat the owner a call to get his thoughts. Phone # 414-352-2886 Good luck whatever direction you go!