Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Door Locks

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REMOVAL & INSTALLATION



Samurai Models

See Figures 1, 2 and 3

  1. Remove the inner door 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. Disconnect all actuating rods from the door lock mechanism.
  6.  
  7. Remove the door lock mounting fasteners, then remove it from the door. The inside handle is removed along with the door lock assembly.
  8.  

To install:
  1. Position the door lock/inside handle mechanism in the door, then install the mounting fasteners. Tighten the fasteners securely.
  2.  

When installing the door open rod to the lock mechanism, avoid depressing the push plate.

  1. Reattach all of the actuating rods to the door lock mechanism, keeping the following points in mind:

    When installing the door open rod on the outside handle, adjust the rod play clearance to 0.000-0.079 in. (0-2mm) by turning the adjusting joint. (Refer to the accompanying illustration.)
     

  2.  



Click image to see an enlarged view

Fig. Fig. 1: Adjust the door open rod clearance (A) to 0.000-0.079 in. (0-2mm) by turning the adjusting joint (3)



Click image to see an enlarged view

Fig. Fig. 2: Engage the lock rod in the rod pin, then flip the small latch over to secure it in this position



Click image to see an enlarged view

Fig. Fig. 3: Adjust the clearance between the inside handle open lever and the outside lever by moving the control rod (10) in or out



Be sure to engage the lock rod with the rod pin as indicated in the accompanying illustration.
 
If the inside door handle was detached from the door lock mechanism, adjust the clearance between the inside open lever and the outside open lever of the door lock to 0.000-0.079 in. (0-2mm) by moving the inside handle remote control rod in the direction of the arrow in the accompanying illustration.
 

After adjusting the various actuating rods, test the inside handle, the outside handle and the lock knob operation before installing the watershield on the door.

  1. Apply a continuous bead of sealant to the inner face of the door, then install the watershield on the door.
  2.  
  3. Install the door panel.
  4.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 4 through 6

This is a general procedure; certain steps may need alteration for your particular vehicle.

  1. Roll the window up.
  2.  
  3. Remove the door panel.
  4.  
  5. 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.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the common front door lock mechanism used on Sidekick, Tracker, Sidekick Sport and X-90 models



Click image to see an enlarged view

Fig. Fig. 5: If you want to reuse the old watershield, peel it off of the door carefully to avoid ripping or tearing it

  1. Detach the inside and outside door handle rods from the door lock assembly.
  2.  
  3. Disengage the door lock cylinder lock rod from the door lock assembly.
  4.  
  5. Disconnect the door lock knob rod from the door lock assembly.
  6.  
  7. If equipped, detach the wiring harness connector from the door lock assembly.
  8.  
  9. Loosen the door lock assembly mounting screws, then remove the assembly from the door.
  10.  

To install:
  1. Position the door lock assembly in the door, then install and tighten the door lock assembly mounting screws securely.
  2.  
  3. Reattach the knob rod, cylinder lock rod, and the inside and outside door handle rods to the door lock assembly. Adjust the outside handle rod-to-door lock linkage distance to 0.00-0.08 in. (0-2mm).
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Be sure to adjust the outside handle rod-to-door linkage clearance to 0.00-0.08 in. (0-2mm)

  1. If necessary, reattach the wiring harness connector to the door lock assembly.
  2.  
  3. Apply a continuous bead of sealant to the inner face of the door, then install the watershield on the door.
  4.  
  5. Install the door panel.
  6.  

 
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