My brother has finally come down the 1,000km trip to my house.
(Thanks again to everyone who helped troubleshooting his limp mode issues. Turns out one of the vacuum hoses was connected to the wrong thing / didn't go to where it was supposed to.)
OK, so, new issue. Side door alignment. The door seems to have dropped down and doesn't align properly anymore (pictures attached).
I've already had a look at it, loosened the bolts on the bottom of the door and lifted the door and re tightened, but it seemed to make no difference.
Could that lower bracket have bent too much causing the door to drop like this, and if so, can I just remove it from the vehicle, bend it out a bit, then put it back in so the door sits higher? Or is this a different problem entirely?
Bongo side door alignment
Moderators: Doone, westonwarrior
- DazzaJay
- Junior Bongonaut
- Posts: 12
- Joined: Mon May 27, 2024 9:37 am
- Location: Finley, New South Wales, Australia
- Contact:
Re: Bongo side door alignment
Attached is the diagram showing the bracket I'm talking about circled in red.
Re: Bongo side door alignment
Getting the door visually aligned often causes problems as there are supports on all three levels which affect angle of the door and offset from the side. You also need to make sure that the 5 electrical connections don't get too far out of alignment.
On my first Bongo I spent some time trying to make it visually correct with out a lot of success
The weight of the door itself is part of the problem as trying to manually adjust it without external support is a major problem especially when you loosen the bolts, the weight is then removed from the van and the suspension comes into play to move the vans alignment!!
On my first Bongo I spent some time trying to make it visually correct with out a lot of success

Geoff
2001 Aero V6, AFT, full side conversion.
2001 Aero V6, AFT, full side conversion.
- DazzaJay
- Junior Bongonaut
- Posts: 12
- Joined: Mon May 27, 2024 9:37 am
- Location: Finley, New South Wales, Australia
- Contact:
Re: Bongo side door alignment
After having a good look at the van today, the adjustment for the door was already in the maximum height position.
My brother informed me that the van was once crashed into a ditch at about 80km/h. (No obvious panel damage, but the plastic air scoop underneath that directs air into the intercooler is smashed up....
Either way, I got my laser level out and shined it around the top and bottom of the van both sides, and it looks like the entire van body is slightly bent on the sliding door side. (Maximum of 5mm), but it seems that's the reason why the door doesn't align properly, and why there's no adjustment left for it.

My brother informed me that the van was once crashed into a ditch at about 80km/h. (No obvious panel damage, but the plastic air scoop underneath that directs air into the intercooler is smashed up....
Either way, I got my laser level out and shined it around the top and bottom of the van both sides, and it looks like the entire van body is slightly bent on the sliding door side. (Maximum of 5mm), but it seems that's the reason why the door doesn't align properly, and why there's no adjustment left for it.
