Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Back Door

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Only hard-top Samurai, Sidekick, Tracker and Sidekick Sport models are equipped with a back door; soft-top Samurai, Sidekick and Tracker models are equipped with tailgates, and the X-90 model is equipped with a trunk lid.

REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

An assistant is necessary to safely remove the back door, because of its weight, from the vehicle.

If you own a Sidekick, Tracker or Sidekick Sport, before proceeding with this procedure, purchase new inner back door panel retainers from a dealership or an aftermarket automotive parts store. The retainers are plastic, and the old ones will most likely break during panel removal.

  1. If applicable, remove the spare tire from the mounting bracket.
  2.  
  3. Open the back door.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the common back door and lock mechanism

  1. Remove the back door balancer from the door and vehicle body.
  2.  
  3. Using a floor jack with a soft-faced pad or folded towel on the jack support pad, slightly support the back door.
  4.  
  5. On Samurai models, remove the inner back door trim panel by loosening all of the retaining screws. Separate the panel from the back door.
  6.  
  7. On Sidekick, Tracker and Sidekick Sport models, remove the inner back door panel plastic retainers by pressing the center pin of the retainer in until the retainer is fully disengaged, then pull the entire retainer out of the inner back door panel. Separate the panel from the back door.
  8.  
  9. Carefully remove the watershield from the inside of the back door. If the watershield is not damaged during removal, it can be reused. Otherwise a new one must be purchased, or you can fabricate one out of a plastic lawn bag.
  10.  
  11. Disengage the license plate light wiring harness connectors from the vehicle wiring harness connectors. Then, pull the vehicle wiring harness out of the back door, making sure not to damage the rubber boot seal.
  12.  
  13. If equipped, remove the spare tire mounting bracket from the outside of the back door by loosening the mounting bolts.
  14.  
  15. If the original back door is going to be reinstalled, matchmark the hinge positions on the back door.
  16.  
  17. Remove the hinge-to-back door retaining bolts, then carefully lift the back door away from the vehicle.
  18.  



Click image to see an enlarged view

Fig. Fig. 2: To remove the back door, first detach the door support ...



Click image to see an enlarged view

Fig. Fig. 3: ... then disengage the door open stop from the vehicle body by removing the door open stop pin



Click image to see an enlarged view

Fig. Fig. 4: Remove the hinge-to-door bolts, then lift the door off of the vehicle

  1. If the back door is going to be replaced with another back door, transfer the following components to the new back door:

    Back door trim panel and watershield
     
    Back door lock and latch
     
    Spare tire mounting bracket
     
    License plate holder
     
    License plate light and back door handle housing
     
    Back door wiring harness
     

  2.  

To install:
  1. Using your assistant's help, support the back door on the padded floor jack and maneuver it close to the vehicle. Position the back door so that the hinges can be situated against the back door and vehicle body.
  2.  
  3. Install the back door hinge retaining bolts finger-tight.
  4.  
  5. Align the back door in the back door opening, as described later in this section.
  6.  
  7. Tighten the hinge-to-back door bolts securely.
  8.  
  9. Route the vehicle wiring harness into the back door, ensuring that you do not damage the rubber boot seal, then reattach all of the applicable wiring harness connectors.
  10.  
  11. If equipped, position the spare tire mounting bracket against the outside of the back door, then install the mounting bolts. Tighten the bolts securely.
  12.  
  13. Apply a continuos bead of sealant on the inside of the back door, then install the watershield.
  14.  
  15. Position the inner back door panel against the inside of the back door.
  16.  
  17. On Samurai models, install and tighten the inner door trim panel retaining screws.
  18.  
  19. On Sidekick, Tracker and Sidekick Sport models, insert new plastic retainers in the panel mounting holes. Engage the retainers by depressing the retainer center pins until they are flush the rest of the retainer.
  20.  
  21. Reinstall the back door balance to the vehicle body and back door.
  22.  
  23. Carefully close and open the back door to ensure that it is properly aligned to the body.
  24.  
  25. If equipped, install the spare tire onto the mounting bracket.
  26.  

ADJUSTMENT



Adjust the back door in the same manner as the tailgate. Refer to the tailgate adjustment procedure.

 
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