Isuzu Cars and Trucks 1981-1991

Doors

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REMOVAL AND INSTALLATION
RWD I-Mark

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

  1. If door is equipped with power accessories or front door speakers, the inside door panel must be removed to disconnect the wiring harness. See illustrations for locations of inside door panel fasteners.
  2.  
  3. Fully open and balance door on a floor jack (an assistant may be needed). Use a bundled rag or a block of wood to protect the painted surface of the door edge.
  4.  
  5. Remove the door checker rivet with a hammer and a chisel (punch).
  6.  
  7. Remove the door hinge plugs that cover the door hinge pins.
  8.  
  9. Using a hinge pin removal tool (J-21688-01), remove the upper and lower hinge pins.
  10.  
  11. Slowly pull the door away from the hinges.
  12.  

To install:

  1. Clean surfaces of 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 and align two halves of hinge.
  4.  
  5. Using a hammer and punch, install hinge pins in the same direction of removal. First the upper, then the lower. Replace hinge plugs. Remove floor jack.
  6.  
  7. Install new rivet on door checker and secure with caulking.
  8.  
  9. Close door slowly to check alignment. DO NOT slam door closed.
  10.  



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Fig. Removing the door hinge pins RWD I-Mark

  1. Adjust the door using the following procedure:
  2.  
    1. Move the door UP by putting a piece of metal over the lower hinge and closing the door.
    2.  
    3. Move the door DOWN by putting a piece of metal over the upper hinge and closing the door.
    4.  
    5. Move the door IN by putting a rubber hammer between the door and pillar, just under the window frame, and push the lower part of the door in.
    6.  
    7. Move the door OUT by putting a rubber hammer between the lower part of the door and pillar and pushing the center of the door in.
    8.  
    9. Move the door FORWARD by disconnecting the door checker and opening the door wide enough to bend the hinges.
    10.  
    11. Move the door REARWARD by putting a piece of metal over the upper and lower hinges and closing the door.
    12.  
    13. Poor sealing in the upper part of the door is corrected by hitting the outer door panel with a rubber hammer or hitting the weatherstrip flange with a hammer.
    14.  
    15. Poor sealing in the lower part of the door is corrected be hitting the weatherstrip flange with a hammer.
    16.  

  3. Reconnect door accessory wiring harness.
  4.  
  5. Install all previously disconnected inner door panel components.
  6.  



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Fig. Moving the door UP RWD I-Mark



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Fig. Moving the door DOWN RWD I-Mark



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Fig. Moving the door OUT RWD I-Mark

All Except RWD I-Mark

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

  1. If door is equipped with power accessories or front door speakers, the inside door panel must be removed to disconnect the wiring harness. See illustrations for locations of inside door panel fasteners.
  2.  
  3. Fully open and balance door on a floor jack (an assistant may be needed). Use a bundled rag or a block of wood to protect the painted surface of the door edge.
  4.  
  5. Remove the door checker pin with a hammer. Place a block of wood under the checker to prevent bending it while removing the pin.
  6.  
  7. Remove the door-side hinge mounting bolts
  8.  
  9. Slowly pull the door away from the hinges.
  10.  



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Fig. FWD I-Mark door hinges



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Fig. RWD Impulse door hinges



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Fig. P'up/Amigo door hinges



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Fig. Door checker



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Fig. Rodeo door assembly

To Install:

  1. Clean and lubricate the hinges, hinge bolt holes and door checker assembly with grease.
  2.  
  3. Balance door on floor jack and align the door with the hinges.
  4.  
  5. Install door-side hinge bolts and tighten with moderate torque. DO NOT tighten down all the way.
  6.  
  7. Remove floor jack and close door slowly to check alignment. DO NOT slam door closed. In most cases door adjustment will be necessary.
  8.  
  9. Open door, loosen hinge bolts and adjust door so that all clearances are even. Hold clearance as far as possible.
  10.  


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

  1. After alignment is satisfactory, tighten door-side hinge bolts to 18-25 ft. lbs.
  2.  
  3. Adjust door striker by loosening mounting screws and tapping with a plastic hammer. The striker should be parallel with the dovetail on the door latch mechanism. One or two shims are needed to control correct engagement of striker with door latch. Torque striker screws to 10 ft. lbs.
  4.  

 
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