SAVE: Lock Repair on 200 Front Doors

["Al Powell" <APOWELL@agcom.tamu.edu>]

After getting help from others, I need to re-pay their kindness by 
posting this.  Here's a summary of the procedure to get at/repair 
door handle or lock parts, based on work done on my 1990 200.  

The event occasioning this exercise for me was a broken lock link 
which rendered the driver's door incapable of locking or unlocking 
the doors. 

I promise that this is MUCH less work than trying to do such 
work without removing the inner door panel.

NOTE: Put window in full UP position before beginning.

1)  Remove outer door (cosmetic) panel.

2)  Remove plastic sheeting by carefully prying out clips at top of 
door.

3)  Loosen inner door by the following process:
- Remove two bolts at lower corners; note number of spacers in each.
- Remove one bolt each at leading and trailing edge of door; front bolt 
may be concealed under weatherstrip.
- Remove two smaller bolts in center top of door panel.

Inner door panel is now loose.

4)  Direct your attention the to lower, rear edge of door; disconnect the 
electrical connections and vacuum hose connection to allow movement 
of the panel.

5)  Panel is now loose, and may be lifted upwards to clear bottom 
edge of door shell.  Have an assistant handy to balance the door.  A 
stool or chair should be used to sit the inner door panel on - then the 
assistant only steadies it, rather than holding it up (for a long 
time...)

6)  At this point, you can move the door panel 8" or so away from the 
door shell.  This allows you to see and work on the door lock 
mechanism.

7)  If you are replacing the lock cylinder, be careful when removing 
the clip which retains the door lock link on the back of the key
cylinder.  There is a circular spring with two angled ends underneath 
this link - and without either seeing its placement or having the Bentley 
to show you how it goes (and it ain't easy to figure out even then) its 
re-installation will stump you.

If upgrading to the new style (stronger) lock link and matching 
key cylinder.......

8)  Insert key and remove lock cylinder from front of door.  If 
necessary, using Torx screwdriver bit, remove machine screw 
holding door handle in place so that you can move pieces around.  

9)  Take cylinder to a clean area; remove key, then carefully remove 
each tumbler AND the tiny spring which fits under the shoulder of each 
tumbler.  Insert each spring into the new cylinder before inserting each 
tumbler.  A bit of grease on each tumbler will help it stay in place.  
When all tumblers are in place, insert the key and it should retract all 
of them.

10)  Re-insert cylinder in door handle; install spring; put new lock 
link over back end of cylinder; using circlip pliers, install 
circlip.  (Repeat attempt as often as needed to succeed...)

Once new link is in place, re-assembly is the reverse of installation.
(And the check is in the mail.....)  BEFORE closing up the door, lube 
all pivot points in lock linkage, and re-connect electrical and 
vacuum connections.

Hope this helps some of you.

Al Powell                           Voice:  409/845-2807
107 Reed McDonald Bldg.             Fax:    409/862-1202
College Station, TX 77843           Email:  a-powell1@tamu.edu 
W3 page - http://agcomwww.tamu.edu/agcom/satellit/alpage.htm
"Baseball is 90 percent mental.  The other half is physical"...
...Yogi Berra.