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Pelican Technical Article:

Rear Door Panel Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$200

Talent:

**

Tools:

Plastic prying tool, door panel clip tool, T25 and T30 Torx drivers

Applicable Models:

Mercedes-Benz E320 (2003-09)
Mercedes-Benz E500 (2003-06)
Mercedes-Benz E55 AMG (2003-06)

Parts Required:

Door panel, vapor barrier, vapor barrier seal, door panel clips

Hot Tip:

Have door panel trim clips on hand in case they break when removing

Performance Gain:

Access to items behind door panel

Complementary Modification:

Replace vapor barrier

The interior door panel has to be removed to access components behind it, such as the door speaker, door module, window regulator, door latch and door handle bracket. Once the door panel is removed, you can replace many components on it such as the armrest and wood trim. You can also replace the power window switch.

In this tech article, I will go over the steps involved in removing the rear door panel on your W211. I suggest having extra door panel clips on hand before removing the panels, as the clips can often break when removing. If you have to remove the vapor barrier, have vapor barrier sealant on hand. Be very careful when removing the vapor barrier. It tears easily and if it is reinstalled with a tear, an interior water leak can develop. There are a few differences in removing the front and rear door panels. This tech article covers the rear. See our tech article on front door panel removing, should you need access to what is behind your front door panels.

Remember your car may have been serviced before and parts replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

The integrated rear sun-shade (green arrow) commonly wears out over time, tearing or developing holes.
Figure 1

The integrated rear sun-shade (green arrow) commonly wears out over time, tearing or developing holes. Once the door panel (red arrow) is removed, we will highlight how to remove it.

Working at the outer edge of the door panel, using a plastic prying tool, remove the side airbag fastener trim cover (red arrow).
Figure 2

Working at the outer edge of the door panel, using a plastic prying tool, remove the side airbag fastener trim cover (red arrow). Then remove the T30 Torx fastener behind it (green arrow).

Working at the center of the door panel below the pull handle, remove the small plastic cover.
Figure 3

Working at the center of the door panel below the pull handle, remove the small plastic cover. Lever the cover out using a plastic prying tool. Then pull it down to remove it.

Pull the trim cover down to remove it.
Figure 4

Pull the trim cover down to remove it. Then remove the two T30 Torx fasteners (red arrows).

Working at the door latch, remove the T20 Torx fastener (green arrow).
Figure 5

Working at the door latch, remove the T20 Torx fastener (green arrow). Then remove the plastic latch trim (red arrow).

Working at the inside of the door panel, remove the ashtray.
Figure 6

Working at the inside of the door panel, remove the ashtray. Open the ashtray. Then detach the locking tabs (red arrows) using a trim panel tool. Remove the ashtray from the door.

Working inside the door panel where the ashtray was removed, remove the T30 Torx fastener (green arrow).
Figure 7

Working inside the door panel where the ashtray was removed, remove the T30 Torx fastener (green arrow). Then disconnect the electrical connectors (red arrows) by pressing the release tab and pulling it straight out.

Using a door panel clip tool (red arrows), release the door panel clips.
Figure 8

Using a door panel clip tool (red arrows), release the door panel clips. I like to start at the lower corner. I then work my way around the door panel, releasing all the other clips.

Once the door panel clips have been disconnected, lift the door panel up (red arrow) to remove it from the door.
Figure 9

Once the door panel clips have been disconnected, lift the door panel up (red arrow) to remove it from the door. It will not come off just yet. You have to detach the door handle cable and an electrical connector.

Pull the door panel back enough to access the door handle cable.
Figure 10

Pull the door panel back enough to access the door handle cable. Pull the cable away (green arrow) from the handle (red arrow) and remove it from the mount. Then unhook the cable end from the handle.

Pull the door panel back enough to access the electrical connector.
Figure 11

Pull the door panel back enough to access the electrical connector. Remove the wiring harness from the holder (green arrow). Disconnect the electrical connector (red arrow) pulling it straight out. Once the electrical connector is disconnected and detached from the door panel, remove the door panel from the vehicle. You can now service items behind the door panel and repair them as needed. When installing, reverse the order of the removal instructions. Be sure to replace any damaged door panel clips. Properly route all the wiring as it was before. If you need to replace the sunshade, see the following steps.

To replace the sunshade, start by removing the five T20 Torx fasteners (red arrow).
Figure 12

To replace the sunshade, start by removing the five T20 Torx fasteners (red arrow). The center fastener may be covered by insulation. Peel it back if necessary (inset).

Using a plastic prying tool, lever the door panel out of the channel in the sunshade.
Figure 13

Using a plastic prying tool, lever the door panel out of the channel in the sunshade.

Once levered apart, remove the sunshade from the door panel.
Figure 14

Once levered apart, remove the sunshade from the door panel. When reinstalling the sunshade, use both hands to squeeze and snap the sunshade and door panel together.

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