ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Doors

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REMOVAL & INSTALLATION



Except Hombre

See Figures 1, 2, 3, 4, 5, 6 and 7



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Fig. Fig. 1: Front door hinge assembly-Pick-up and Amigo



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Fig. Fig. 2: Front door and hinge assembly-Trooper and Rodeo



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Fig. Fig. 3: Rear door and hinge assembly-Trooper and Rodeo



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Fig. Fig. 4: An example of the door wire harness connector, where equipped



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Fig. Fig. 5: Use a plastic-faced hammer to remove the checker rivet



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Fig. Fig. 6: Scribe an alignment mark around both door hinges-Trooper shown



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Fig. Fig. 7: Use a suitable sized wrench or socket to remove the hinge retainer bolts

To prevent door glass from breaking, lower glass prior to removal or alignment of the door.

  1. Disconnect the negative battery cable.
  2.  
  3. Scribe alignment marks around the hinges on the vehicle pillar.
  4.  
  5. If door is equipped with power accessories or front door speakers, the inside door panel must be removed to disconnect the wiring harness. Refer to the door panel removal and installation procedure in this section.
  6.  
  7. Fully open and balance door on a floor jack, or have an assistant support the door. Use a bundled rag or a block of wood to protect the painted surface of the door edge.
  8.  
  9. Remove the door checker rivet with a plastic-faced hammer and a chisel (punch).
  10.  
  11. Remove the door hinge plugs that cover the door hinge bolts, if equipped.
  12.  
  13. Remove the door-side hinge mounting bolts
  14.  
  15. Slowly pull the door away from the vehicle.
  16.  

To install:
  1. Clean the surfaces of the hinges with sandpaper to remove any burrs. Lubricate the hinges and the inside of the door pin hole with grease.
  2.  
  3. Balance door on floor jack, or have an assistant support the door and align the hinges with the mounting holes.
  4.  
  5. Install door-side hinge bolts and tighten with moderate torque. DO NOT tighten down all the way.
  6.  
  7. Remove the floor jack and close the door slowly to check alignment. DO NOT slam the door closed. In most cases, some door adjustment will be necessary.
  8.  
  9. Open the door, and loosen the hinge bolts to adjust the door so all clearances are even. Refer to the adjustment procedure in this section for details.
  10.  

It may be necessary to loosen the door-side and/or body-side hinge bolts to correctly adjust the door. Body shims may be necessary to adjust the door or striker with body.

  1. After alignment is satisfactory, tighten the door hinge bolts to 18-25 ft. lbs. (23-32 Nm).
  2.  
  3. Install new rivet on door checker.
  4.  
  5. Reconnect door accessory wiring harness, if removed.
  6.  
  7. Install all previously disconnected inner door panel components.
  8.  
  9. Connect the negative battery cable.
  10.  

Although the door hinges can be removed from either the door or the body pillar, removal and installation is easier if the hinge bolts are removed from the A-pillar.

Hombre

See Figures 8, 9, 10 and 11



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Fig. Fig. 8: Door assembly and wire harness, where equipped-Hombre



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Fig. Fig. 9: An example of a tool used to compress the door hinge spring



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Fig. Fig. 10: Door hinge pin and retainer clip



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Fig. Fig. 11: Door hinge pin placement and installation direction

To prevent door glass from breaking, lower glass prior to removal or alignment of the door.

  1. Disconnect the negative battery cable.
  2.  
  3. If door is equipped with power accessories or front door speakers, the inside door panel must be removed to disconnect the wiring harness. Refer to the door panel removal and installation procedure in this section.
  4.  
  5. Fully open and balance door on a floor jack, or have an assistant balance the door. Use a bundled rag or a block of wood to protect the painted surface of the door edge.
  6.  
  7. Disconnect the door hinge spring using tool J-36604 or equivalent.
  8.  
  9. Remove the door hinge pins using a plastic-faced hammer. Start with the lower pin, then move to the upper pin.
  10.  
  11. Once the pins are removed, slowly pull the door away from the vehicle.
  12.  

To install:
  1. Clean the surfaces of the hinges with sandpaper to remove any burrs. Lubricate the hinges and the inside of the door pin hole with grease.
  2.  
  3. Balance door on a floor jack, or have an assistant support the door.
  4.  
  5. With the aid of an assistant, position the door to the vehicle pillar, and align the hinge holes.
  6.  
  7. Install the lower hinge pin, then the upper hinge pin. Tap the hinge pins into place using a plastic-faced hammer
  8.  
  9. Remove floor jack and close door slowly. DO NOT slam the door closed. If the door does not close or align properly, the hinges will have to be removed, and replaced with new. On these models, there is no provision for adjustment.
  10.  
  11. Install new rivet on door checker and secure with caulking.
  12.  
  13. Reconnect door accessory wiring harness, if removed.
  14.  
  15. Install all previously disconnected inner door panel components.
  16.  
  17. Connect the negative battery cable.
  18.  

HINGE REPLACEMENT



Except Hombre

When replacing hinges, it is recommended to replace both hinges instead of just one.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the door from the vehicle.
  4.  
  5. Scribe alignment marks around the hinge on the door.
  6.  
  7. Remove the retainer bolts securing the hinge to the door.
  8.  
  9. Remove the hinge from the door. Clean around the hinge contact surface.
  10.  

To install:
  1. Position the hinge to the door, making sure it aligns with the marks made during removal.
  2.  
  3. Secure the hinge to the door using the retainer bolts. Tighten the bolts to 18-25 ft. lbs. (23-32 Nm).
  4.  
  5. Install the door on the vehicle. Align properly.
  6.  
  7. Connect the negative battery cable.
  8.  

Hombre

See Figures 12, 13, 14 and 15



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Fig. Fig. 12: Center the drill bit and drill out the spot weld-Hombre



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Fig. Fig. 13: Use a chisel to separate the hinge



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Fig. Fig. 14: Replacement hinge components-body side



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Fig. Fig. 15: Replacement hinge components-door side

When replacing hinges, it is recommended to replace both hinges instead of just one.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the door from the vehicle.
  4.  
  5. Scribe reference marks around the hinge on the door and vehicle pillar.
  6.  
  7. Use a center punch and mark the location of each spot weld securing the hinge to the door and pillar.
  8.  
  9. Using a 1 / 8 in. (3mm) drill bit, drill out each spot weld in the hinge. After each weld has been drilled, use a 1 / 2 in. (13mm) drill bit, and drill each hole again.
  10.  
  11. Use a hammer and chisel or equivalent between the door and hinge to separate the hinge.
  12.  
  13. Clean the hinge contact surface of any burrs or rust. If any bare metal is exposed, paint it with automotive paint to prevent rust.
  14.  
  15. Position a bolt in the replacement hinge and attached tapped plate, and align the hinge within the scribe mark made during the removal phase.
  16.  
  17. Install the bolt and hand-tighten. Install the remaining hinge bolts. When all the bolts are installed, go back and tighten each bolt to 26 ft. lbs. (35 Nm).
  18.  
  19. Install the door and adjust.
  20.  
  21. Connect the negative battery cable.
  22.  

ADJUSTMENT



Except Hombre

See Figure 16



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Fig. Fig. 16: Example of alignment checking positions

Whenever adjusting a door, always adjust in small increments.

A door can be adjusted at either the hinge or the door striker, or in extreme conditions, both locations.

Before adjusting the striker, check and make sure the clearance between the door and vehicle body is the same around all sides of the door. If the clearance is the same, and further hinge adjustment does not proper align the door, then adjust the striker plate.

HINGE
  1. Close the door and determine whether the door has to be moved up, down, in or out.
  2.  

If the door is misaligned at one location more than another, then only one hinge should be adjusted.

  1. Loosen, but do not remove the hinge bolts; 2-3 turns should be enough the adjust the hinge.
    1. If the door needs to be moved out, once the bolts are loosened, carefully move the door outwards in small increments.
    2.  
    3. If the door needs to be moved in, once the bolts are loosened, carefully press the door inwards in small increments.
    4.  
    5. If the door needs to be moved to the left, once the bolts are loosened, carefully move the door left in small increments.
    6.  
    7. If the door needs to be moved to the right, once the bolts are loosened, carefully move the door right in small increments.
    8.  

  2.  
  3. After each adjustment, tighten the bolts and close the door. Check the alignment. Continue to adjust until correct.
  4.  
  5. When the door adjustment is correct, tighten each bolt to 18-25 ft. lbs. (23-32 Nm).
  6.  

In some cases, shims will have to be placed between the hinge and vehicle pillar to correctly align the left and right clearances. In this case, install one shim at a time between the hinge and door, then adjust as outlined.

Be patient when adjusting the door; this procedure requires a great deal of trial and error to get it correct.

STRIKER PLATE

See Figures 17 and 18



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Fig. Fig. 17: Painting a scribe mark around the striker plate for reference during adjustment



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Fig. Fig. 18: Loosen the striker plate retainer screws to adjust the plate

  1. Scribe an alignment mark around the striker plate for reference during the adjustment procedure.
  2.  
  3. Loosen the mounting screws and carefully tap the striker plate with a plastic-faced hammer.
  4.  

The striker should be parallel with the dovetail on the door latch mechanism.

  1. In the event engagement of striker with door latch does not take place, install 1 or more shims between the striker plate and the vehicle pillar.
  2.  
  3. When complete, tighten the striker screws to 10 ft. lbs. (13 Nm).
  4.  

Hombre
HINGE

Because of the permanent mounting method of the Hombre hinge, adjustment of the hinge is not possible. In the event a door will not close or align properly, the hinge will have to be replaced. Refer to the hinge replacement procedure in this section.

STRIKER PLATE
  1. Loosen the mounting screws and carefully tap the striker plate with a plastic-faced hammer.
  2.  

The striker should be parallel with the dovetail on the door latch mechanism.

  1. In the event engagement of striker with door latch does not take place, install one or more shims between the striker plate and the vehicle pillar.
  2.  
  3. When complete, tighten the striker screws to 10 ft. lbs. (13 Nm).
  4.  

 
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