Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

EXTERIOR

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REMOVAL & INSTALLATION



All Models

See Figure 1

This is a general procedure; certain steps may need alteration for your particular vehicle. Also, an assistant is required to safely remove the door from the vehicle, due to the weight of the door.

  1. Open the door.
  2.  
  3. Use a pair of pliers to pull, or a mallet to drive, the retaining pin up and out of the door stopper strap and door pillar bracket.
  4.  
  5. Using a floor jack with a soft-faced pad or folded towel on the jack support pad, slightly support the door.
  6.  
  7. If equipped, disengage any applicable vehicle wiring harness connectors from the door harness connectors.
  8.  
  9. If the original door is going to be reinstalled, matchmark the hinges to the door.
  10.  



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Fig. Fig. 1: Exploded view of the upper and lower hinge mounting-Sidekick, Tracker, Sidekick Sport and X-92 models

  1. Remove the hinge-to-door retaining bolts, then carefully lift the door away from the vehicle.
  2.  
  3. If the front door is going to be replaced with another door, transfer the following components to the new door:
  4.  



Front door trim panel and watershield
 
Door lock and door latch
 
Window regulator, equalizer arm bracket and door glass
 
Door wiring harness
 

To install:
  1. Using your assistant's help, support the door on the padded floor jack and maneuver it close to the vehicle. Position the door so that the hinges can be situated against the door.
  2.  
  3. Install the door hinge retaining bolts finger-tight.
  4.  
  5. Align the door in the door opening, as described later in this section.
  6.  
  7. Tighten the hinge-to-door bolts securely.
  8.  
  9. Reattach all applicable wiring harness connectors.
  10.  
  11. Reinstall the retaining pin so that the door stopper strap is properly engaged with the door pillar bracket.
  12.  
  13. Carefully close and open the door to ensure that it is properly aligned to the body.
  14.  

ADJUSTMENT



See Figures 2, 3, 4 and 5

The door hinges allow sufficient movement to correct most door misalignment conditions. The hinge mounting holes are elongated to provide movement for door alignment.



Click image to see an enlarged view

Fig. Fig. 2: When properly aligned, the distance between the door edge and the door pillar surface should be 2.22-2.26 in. (32-32mm)-Samurai models

Never attempt to remedy door misalignment solely by repositioning the latch striker.

  1. To adjust the up-down position of the entire door, or to adjust the in-out position of the front edge of the door, perform the following:
  2.  

  1. Determine which hinge bolts are to be loosened and back them out just enough to allow movement.
  2.  
  3. Move the door safely by using a padded pry bar to correct the misalignment condition. When the door is in the proper position, tighten the bolts securely, then check door operation. There should be no binding or other interference when the door is either closed or opened.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: To fine-tune the striker position, loosen the mounting screws, then move the striker as necessary



Click image to see an enlarged view

Fig. Fig. 4: The striker should be positioned so that the clearance (C) between the top of the striker bar and the bottom edge of the door lock arm (when the door is open) is 2.24 in. (2mm)-Samurai models



Click image to see an enlarged view

Fig. Fig. 5: On Sidekick, Tracker, Sidekick and X-92 models, the striker should be positioned so that it properly engages the door lock arm, as shown

  1. Repeat sub-steps 2a and 2b until the door is properly aligned in the door opening. The gap between the edge of the door and the body should be uniform all around the door's perimeter.
  2.  

  1. To adjust the in-out position of the rear edge of the door, perform the following:
  2.  

  1. Loosen the door latch striker mounting screws, then position the striker up and down until the center of the striker is aligned with the center of groove C on the door latch.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Although not normally necessary, the striker can be adjusted fore-and-aft by adding or removing shims, respectively

  1. Move the striker in or out so that the door will be flush with the body metal when closed.
  2.  
  3. If it is necessary to move the striker fore or aft, add or remove shims from beneath the striker plate. The distance between the rear face of the door should be 2.499-2.579 in. (22.7-24.7mm) for Samurai models, 2.52-2.57 in. (22.6-24.6mm) for Sidekick, Tracker and Sidekick Sport models, or 2.44-2.52 in. (22.2-23.2mm) for X-92 models from the front face of the body in the door opening.
  4.  
  5. Tighten the striker screws securely.
  6.  

  1. Lubricate the striker joints with oil or multi-purpose grease.
  2.  

 
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