DII front passenger door won't open

[winaje]

Hi guys, I have recently replaced the shell of the front passenger door of my '00 DII, using all of my old parts. The door seemed to open and shut OK, apart from a slightly sticky outer handle. However, it is now stuck shut. It's currently at the mechanics getting ready for final inspection for roadworthy. I'm going around there Sunday night to try and get the bloody thing to open etc. It seems that the central locking is working OK, but neither the inner or outer handles will open the door. The mech has tried pushing and pulling etc.

Has anyone had this happen previously? Are there any tips and/or pointers you can give me to look out for? What's worst case; do I have to basically cut the door off the car and buy another one...!?!

TIA, Will

[Lucus]

you may need to take the seat out so you can open up the inner door skin and operate the lock mechanism manually

[winaje]

Thanks for the reply Lucus. I should have mentioned that this has already been done.

The thing that concerns me most is, where do I go from here, if I cannot make the lock mechanism work at all even when manipulating it directly?

Thanks, Will

[eddie_tdi]

try putting the key into the lock and turning it as if you were to unlock it (even if it is already unlocked), and then operate the door handle at the same time.. this is what i have to do with mine sometimes as i have to replace the door lock springs

good luck

[winaje]

try putting the key into the lock and turning it as if you were to unlock it (even if it is already unlocked), and then operate the door handle at the same time.. this is what i have to do with mine sometimes as i have to replace the door lock springs

good luck

Thanks for the reply Eddie. The only problem is that as it is the passenger door, there is no lock to put the key in...

[eddie_tdi]

oh thats right, the D2's dont have a lock on the passenger front door... My bad. Try to open it from the inside while holding the lock button up with the other hand.. maybe that might work..

[eddie_tdi]

any luck?

[winaje]

Will find out tomorrow night when I go and try to get the door open. I'll keep you all informed as to what happens and how we get the door open (assuming we can).

Thanks, Will

[tdi130dualcab]

Did you connect the electrics?
I believe that the security system completely disconnects the door latch mechanism, so you may need to have it connected, then arm/disarm the security.

[winaje]

Now THAT is something I didn't think about. Yes, the electrics were connected and tested, but not sure if the mechanic has armed/disarmed the security. He is going to spew blood if I turn up there tonight, hit the button on the key, and the door unlocks...!!!

[winaje]

Ok, firstly thanks for all the replies.

We got the door open, and the problem was my fault, dammit. When I reinstalled the locking mechanism in the new door shell, I accidentally reassembled the link rod from the external handle incorrectly. I had installed the rod on the wrong side of the lock slot, which caused the rod connector block to be trapped between the lock mechanism and the door frame. We removed the lock, assembled it correctly, reinstalled and the door opened and shut perfectly.

Thanks again.