Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Door Panels

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REMOVAL & INSTALLATION



Samurai Models
  1. Remove the window regulator crank handle by using a tool designed specifically for this purpose.
  2.  
  3. Remove the inside door handle trim by loosening the retaining screw. Pull the door handle out and slide the trim off of the handle.
  4.  
  5. Loosen the two inside pull handle mounting screws, then separate the pull handle from the door panel.
  6.  
  7. Loosen the two screws retaining the stopper band to the door, then remove the stopper band.
  8.  
  9. Using a prytool, gently separate the trim panel from the door, disengaging the trim panel retaining clips.
  10.  

To install:
  1. Position the door panel on the door so that the retaining clips are aligned with the holes in the door, then press the door panel against the door until all of the retainers are completely engaged.
  2.  
  3. Install the snap-ring on the window crank handle, then press the handle onto the regulator shaft. The handle should be positioned so that when the window is fully closed, the handle points forward and upward at a 45 degree angle.
  4.  
  5. Position the pull handle against the door panel, then install and tighten the two mounting screws.
  6.  
  7. Install the stopper band and mounting screws.
  8.  
  9. Install the inside door handle trim and screw.
  10.  

Sidekick, Tracker, Sidekick Sport and X-90 Models

See Figures 1 through 12

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

  1. Remove the inside door handle trim by loosening the retaining screw.
  2.  



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Fig. Fig. 1: Exploded view of door panel mounting-Sidekick, Tracker and Sidekick Sport models



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Fig. Fig. 2: Exploded view of the door assembly, showing door panel mounting-X-90 models

  1. Remove the side mirror inner trim piece by gently prying it away from the door surface.
  2.  
  3. Loosen the two armrest mounting screws, then separate the armrest from the door panel.
  4.  



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Fig. Fig. 3: To remove the door panel, loosen the inside door handle trim screw ...



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Fig. Fig. 4: ... and, if equipped, the pull handle case screw ...



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Fig. Fig. 5: ... then lift the pull handle case up and out of the door panel



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Fig. Fig. 6: This tool is specifically designed to remove window crank handle retaining snaprings



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Fig. Fig. 7: Align the tool with the handle, then slide it underneath and disengage the snapring



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Fig. Fig. 8: If the special tool is not available, a clean shop rag can be used to work the snapring off of the crank handle



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Fig. Fig. 9: Do not lose the snapring-you will need it for handle installation

  1. If equipped, loosen the retaining screw from the pull handle case, then pull the case up and out of the door panel.
  2.  
  3. Remove the window regulator crank handle by using a tool designed specifically for this purpose. If the tool is not available, use a clean rag to disengage the retaining snapring, as shown in the accompanying illustration.
  4.  
  5. Using a prytool, gently separate the trim panel from the door, disengaging the trim panel retaining clips.
  6.  
  7. Pull the inside door handle inner bezel out from the door panel (almost at a 90 degree angle), then rotate the door trim panel in a counterclockwise direction so that the rear edge moves up and over the inside door handle inner bezel, and the front edge of the trim panel drops down beneath the bezel. In this position, remove the door trim panel from the door.
  8.  



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Fig. Fig. 10: Carefully disengage all of the door panel retaining clips ...



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Fig. Fig. 11: ... then remove the trim panel from the door

To install:
  1. Install the door panel on the door by fitting it over the inside door handle inner bezel (as during removal), and then rotating it clockwise into position.
  2.  
  3. Position the door panel on the door so that the retaining clips are aligned with the holes in the door, then press the door panel against the door until all of the retainers are completely engaged.
  4.  
  5. Install the snapring on the window crank handle, then press the handle onto the regulator shaft. The handle should be positioned so that when the window is fully closed, the handle points forward and upward at a 45 degree angle.
  6.  



Click image to see an enlarged view

Fig. Fig. 12: Install the snapring on the regulator crank handle before assembly

  1. If equipped, insert the pull handle case into the door panel, then install the retaining screw.
  2.  
  3. Position the armrest against the door panel, then install and tighten the two mounting screws.
  4.  
  5. Install the side mirror inside trim piece by aligning the retaining clips with the holes in the door, then press the trim piece against the door until all of the retainers are completely engaged.
  6.  
  7. Install the inside door handle trim.
  8.  

 
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