Drivers Window Issues

You can adjust- one of the lower points that the window mech attaches on the bottom of the door, accessed by a plastic grommet on the base of the door- pop it off, loosen the 10mm bolt which allows for a few mm movement to make the window sit closer or further away from the seal

The door lock isn’t like the old (as you describe) tuning fork mechs- from memory

Take the plastic grommet off the door that sits near the door latch
Insert a hook to slide the metal slider which allows the door handle to Unclip and move up/away
Go back in the same way you unhooked and unscrew the Allen bolt which holds the lock in place
Put the key in the lock and quarter turn it to allow it to be slid out
 
Brilliant! All done, but...now the door won't open from the outside handle. It opens from the first latch (door not fully closed) but not if the door is fully shut. I can feel it pulling on the Bowden cable so I'm guessing it's stretched or damaged. I used my old door handle in the replacement door, as my handle is newer, so I may try the one that came with the door tomorrow, it was working fine before I changed the lock barrel, so I can't see why it won't work now.
 
So this afternoon, in pouring rain, I swapped the outside door handle for the one that came with the door, which looks identical in all respects, and it works perfectly! So, I am nearly done now.

I just need to adjust the window to stop the wind noise, get a couple of dents removed from the door and wing, find out where the heck I've put the tweeter, soundproof the door and put the door card back on. Then Project Z4 will be finished! (although I'll probably find something else to do to it then, still - keeps me out of the wife's way!)
 
GreySquirrel said:
So this afternoon, in pouring rain, I swapped the outside door handle for the one that came with the door, which looks identical in all respects, and it works perfectly! So, I am nearly done now.

I just need to adjust the window to stop the wind noise, get a couple of dents removed from the door and wing, find out where the heck I've put the tweeter, soundproof the door and put the door card back on. Then Project Z4 will be finished! (although I'll probably find something else to do to it then, still - keeps me out of the wife's way!)
Click to expand...
Well done!
That's a fair sized task to take on and more knowledge gleaned to help out others in the future.
It is interesting to see how the knowledge and experience is spreading. I feel the zeds are in good hands.
 
So the following day, the door was again failing to work from the outside handle. So I took the handle and lock off again, and checked the Bowden Cable. As you can see from the photo, it is clearly the reason it wasn't working, with a big kink in the middle. So I practised removing and replacing it on my old door, took my old one off (which is in perfect condition by the way), and then set about replacing the damaged one.

It's not really too hard, and I took several photos and videos, so may make a how-to when I get a chance. Less than an hour later, and with a surprising lack of profanities uttered, the door was working well again. Yet another little win! Now where did I put that ABS sensor...
 

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I believe the West Country is s bit light on zed fixers.
You could be making a niche for yourself. :thumbsup:
 
Well, it looks like I'm finished! Had a dent specialist fix the dents (it's amazing what they can do), I re-fitted the door card and membrane and sorted the slight gap on the window seal. I reset the Airbag code with my Creator 110, then spent an hour changing the rear driver's side speed sensor. Now my dash is warning light-free! I think my list of jobs is complete! Feels oddly anticlimatic.
 
Hi @greySquirrel, where in Devon did you get your dents done? I am in Devon as well with similar door/wing dent that needs doing.

Thanks in advance :)
 
I used an independent chap, who is the brother of one of the mechanics in the garage next to my workplace. I can try and get his details if you like. He's not cheap, but he did a great job. I had a really sharp sent, and it's gone. I can just see it if i catch the light just right, but I'm very fussy and am 100% happy with the finished result.
 
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