Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Door Glass and Regulator

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REMOVAL & INSTALLATION



2-Door Models

See Figures 1 through 5

  1. Remove the door trim panel.
  2.  
  3. Peel the watershield off of the inside face of the door. If the watershield is not excessively damaged during removal (rips or tears may be repaired with waterproof tape), it may be reused. Otherwise, a new one can be purchased or fabricated from a plastic lawn bag.
  4.  
  5. Lower the window all the way down.
  6.  
  7. On X-90 models, remove the window glass stoppers from the top edge of the window opening.
  8.  
  9. Wrap electrical tape around the blade of a putty knife, then use the knife to gently pry the door outside weatherstripping off of the door.
  10.  
  11. Pry the inner weatherstripping off of the door.
  12.  
  13. Loosen the glass bottom channel mounting screws, then lift the glass and bottom channel up and out of the door.
  14.  
  15. Position the door glass on a clean, padded surface.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: After removing the door panel and window glass, loosen the regulator bolts (arrows) and remove the regulator through the large hole at the bottom of the door-X-90 model shown



Click image to see an enlarged view

Fig. Fig. 2: Window regulator mounting screw locations-Sidekick and Tracker

  1. If necessary, the bottom channel can now be removed.
  2.  
  3. If equipped with power windows, detach the wiring harness connector from the regulator wiring harness connector, then loosen the regulator harness holding clamp.
  4.  
  5. Loosen the window regulator mounting bolts, then remove the regulator from the door through hole (A).
  6.  

To install:
  1. Prior to installation, apply multi-purpose grease to the lubrication points shown in the accompanying illustration.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Before installing the regulator, apply multi-purpose grease to the regulator at the points shown (A)

  1. Maneuver the window regulator through the hole in the door and into position. Install the regulator mounting bolts and tighten them securely.
  2.  
  3. If equipped with power windows, reattach the wiring harness connector to the regulator wiring harness.
  4.  
  5. If the bottom channel was removed from the glass, apply soapy water to the bottom channel and carefully tap the channel in place on the glass with a plastic hammer. The channel should be positioned so that the rear hole of the channel is 1.65 in. (42mm) from the bottom, rear corner of the window glass for Samurai models, or 15.69 in. (39.85cm) from the rear edge of the glass for Sidekick and Tracker models.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: If the bottom channel was removed from the glass, install it so that the rear hole is 1.65 in. (42mm) from the lower rear corner-Samurai models



Click image to see an enlarged view

Fig. Fig. 5: On Sidekick and Tracker models, the rear hole of the bottom channel should be 15.69 in. (39.85cm) from the rear corner of the glass

  1. Lower the glass and channel down into the door.
  2.  
  3. Install the bottom channel mounting bolts securely.
  4.  
  5. Adjust the position of the window glass.
  6.  
  7. Install the inner and outer door weatherstripping.
  8.  
  9. On X-90 models, install the window glass stoppers onto the top edge of the window opening.
  10.  
  11. Apply a continuous bead of sealant to the inner face of the door, then install the watershield on the door.
  12.  
  13. Install the door panel.
  14.  

4-Door Models
  1. Remove the door trim panel.
  2.  
  3. Peel the watershield off of the inside face of the door. If the watershield is not excessively damaged during removal (rips or tears may be repaired with waterproof tape), it may be reused. Otherwise, a new one can be purchased or fabricated from a plastic lawn bag.
  4.  
  5. Lower the window all the way down.
  6.  
  7. Wrap electrical tape around the blade of a putty knife, then use the knife to gently pry the door outside weatherstripping off of the door.
  8.  
  9. Pry the inner weatherstripping off of the door.
  10.  
  11. Loosen the glass mounting screws, then lift the glass up and out of the door.
  12.  
  13. Position the door glass on a clean, padded surface.
  14.  
  15. If equipped with power windows, detach the wiring harness connector from the regulator wiring harness connector, then loosen the regulator harness holding clamp.
  16.  
  17. Loosen the window regulator mounting bolts, then remove the regulator from the door through hole (A).
  18.  

To install:
  1. Prior to installation, apply multi-purpose grease to the lubrication points shown in the accompanying illustration.
  2.  
  3. Manueveur the window regulator through the hole in the door and into position. Install the regulator mounting bolts and tighten them securely.
  4.  
  5. Adjust the position of the window glass.
  6.  
  7. If equipped with power windows, reattach the wiring harness connector to the regulator wiring harness.
  8.  
  9. Lower the glass down into the door.
  10.  
  11. Install the glass mounting bolts securely.
  12.  
  13. Install the outer door weatherstripping.
  14.  
  15. Apply a continuous bead of sealant to the inner face of the door, then install the watershield on the door.
  16.  
  17. Install the door panel.
  18.  

DOOR GLASS ADJUSTMENT



X-90 Models

See Figure 6

The window glass should be adjusted up and down so that the top edge of the window is level (as shown in the accompanying illustration). To adjust the front or rear of the window in the up-down orientation, fine-tune the positions of door stops A and B.

If the top edge of the window needs adjusting in or out from the vehicle, perform the following:

  1. Loosen the trim support fixing screws.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Move the various door stops and sashes to adjust the position of the window glass-X-90 models

  1. Move the lower end of the rear sash by adjusting stud bolt B in or out as needed.
  2.  
  3. Move the upper end of the rear sash by moving stud bolt A in or out as necessary.
  4.  
  5. With the window glass fully raised, tighten the trim support fixing screw so that the window is no longer wobbly.
  6.  

Except X-90 Models
FRONT DOORS
See Figure 7

To adjust the position of the window glass, loosen the regulator mounting bolts and move the entire assembly until the glass is properly positioned. The top edge of the glass should be parallel with the top edge of the door, and the back edge of the glass should fit snugly in the rubber weatherstripping groove. Tighten the regulator bolts once the glass is properly adjusted.



Click image to see an enlarged view

Fig. Fig. 7: The window should be adjusted so that its top edge is parallel with the door frame edge, as shown

REAR DOORS

During installation, adjust the window glass position as follows:

  1. Loosen the five screws and two bolts.
  2.  
  3. Using the window regulator crank handle, raise the window completely.
  4.  
  5. Tighten the fasteners marked securely.
  6.  
  7. Lower the window glass fully.
  8.  
  9. Securely tighten the two screws marked 2
  10.  

Refer to the door glass and regulator procedure for details.

 
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