Door Alignment Question
 

Hi everyone,

First post! I've bought or saved a 97 boxster and am nearing the finish line after replacing the whole suspension and rear subframes and all the things that should have been done over the years. I ended up replacing almost all of the body removable body panels as they were pretty chewed up. I'm in the panel alignment phase - and really stuck on the door alignment. It doesn't seem like there is any adjustment and the doors themselves are sagging. They sit correctly when on the strikers but when hanging free are sagging. I see that Cayenne's have door shims but not seeing anything for 986 or 996s. Is there any preferred method on shimming the door or aligning it so it will close properly? Thank you in advance!http://986forum.com/forums/uploads02...1647594804.jpg

Can you post a pic of the sagging when they are open?

If they line up correctly when closed I'm not sure what there is to be done. I've not had to deal with this on a 986 but on other vehicles I've always just adjusted so the gaps are correct with the door closed and called it a win.

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Sounds like the door hinge pins are worn out.
Grab the door at the rear and move it up and down while viewing the hinge at the front of the door. If you can detect any play in the hinge pin, replacing the hinge is the only fix.

From the Sacred Manual, Chapter 57-22, pg 3: Thou shalt undo fastening screw -1-, set the contour in relation to the wing and side member by shifting the angle pieces -3- in their vertical and horizontal positions. [See body gap dimensions]
The settings can be extended by removing the centering sleeve -2-.

Bolt Torque, 23 Nm (17 ft).

http://986forum.com/forums/uploads02...1647657605.jpg

Gap specs:
A - 5 +1 mm
B - 1.6 +-1 mm
C - 4.4 +1 -0.5 mm
D - 4 +1 -0.5 mm

http://986forum.com/forums/uploads02...1647657852.jpg

Thank you guys for the replies - turns out there is a magic tool that can help you bend your hinges into submission for small tweaks such as this - https://www.ebay.com/itm/165468129424?chn=ps&norover=1&mkevt=1&mkrid=711-117182-37290-0&mkcid=2&itemid=165468129424&targetid=12627494901 02&device=c&mktype=&googleloc=9031186&poi=&campaig nid=15428034462&mkgroupid=133947154481&rlsatarget= pla-1262749490102&abcId=9300763&merchantid=135983995&g clid=Cj0KCQjwmuiTBhDoARIsAPiv6L9Xk1tnnExPzPbjXgmE1-MN57eLmO7G7Lkp2BdfI4JkCeFS0-QklHUaAgpWEALw_wcB

I found a friend of a friend who is a body guy and he was able to tweak my doors into closing correctly within 10 minutes.... I've spent so much time on this. Goes to show - a professional is a professional.

@badsurfer67 - the link for eBay no longer works, can you advise on the tool you posted? I have a 99 986 that door gap on the closing side is too narrow, approximately 2mm and I need more. Thinking my only option is door hinge needs to be corrected.

As info, I've already tried removing the plastic around the hinge hole to gain further adjustment - just not there yet.

And yes this car was involved in an accident which damaged the driver door around the hinges - so I'm guessing it pop it a bit!

And thank you @78F350 - great info!!!

Rob