Toyota Celica 1994-1998 Repair Guide

Doors

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REMOVAL & INSTALLATION




WARNING
The doors are heavier than they appear. Support the door from the bottom and use a helper during removal and installation. Do not allow the door to sag while partially attached and do not subject the door to impact or twisting motions.

  1. If equipped with power door locks, windows or any other power option located on the door, remove the inner door panel and disconnect the electrical component.
  2.  
  3. Remove the wire harness retainers and extract the harness from the door.
  4.  
  5. Use a floor jack padded with rags or soft lumber to support the door at its lower midpoint. Use a felt tip marker to outline the hinge position on the door.
  6.  
  7. Disconnect the door check rod. To prevent the rod from falling inside the door, install the retainer into the hole in the end of the check rod.
  8.  
  9. Have a helper support the door, keeping it upright at all times. Remove the bolts holding the upper and lower hinge to the door.
  10.  
  11. Using two people, lift the door clear of the car.
  12.  
  13. The door hinge may be removed from the body if necessary.
  14.  

To install:
  1. If the door hinge is removed from the body, reinstall it and tighten the bolts to 24 ft. lbs. (32 Nm).
  2.  
  3. Place the door in position and support it. Use the jack to fine tune the position until the bolt holes and matchmark (hinge outline) align.
  4.  
  5. Apply an appropriate amount of multipurpose grease to the lower hinge and cam sliding area. Using engine oil, lubricate between the lower hinge pin and the roller.
  6.  
  7. Install the hinge bolts and nuts. Tighten the bolts to 21 ft. lbs. (28 Nm).
  8.  
  9. If all has gone well, the door should almost be in the original position. Refer to the door adjustment procedures to align the door and body. It may be necessary to loosen the hinge bolts and reposition the door; remember to retighten them each time or the door will shift out of place.
  10.  
  11. Once adjusted, connect the door check lever and install the pin. Install the hinge covers if any were removed.
  12.  
  13. Route the wiring harness(es) into the body and connect them to their leads.
  14.  
  15. Test the operation of any electrical components in the door (locks, mirrors, speakers, etc.) and test drive the car, checking the door for air leaks and rattles.
  16.  

ADJUSTMENT



See Figures 1, 2 and 3

To adjust the door in forward, rearward and vertical directions, perform the following adjustment:

  1. Loosen the body side hinge bolts or nuts.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Adjusting the door in the forward/rearward and vertical directions

  1. Adjust the door to the desired position.
  2.  
  3. Secure the body side hinge bolts or nuts and check the door for proper alignment. Tighten the bolts to 21 ft. lbs. (28 Nm).
  4.  

To adjust the door in left, right and vertical directions, perform the following adjustments:



Click image to see an enlarged view

Fig. Fig. 2: Adjusting the door in the left/right and vertical directions

  1. Loosen the door side hinge bolts slightly.
  2.  
  3. Adjust the door to the desired position.
  4.  
  5. Secure the door side hinge bolts and check the door for proper alignment. Tighten the bolts to 21 ft. lbs. (28 Nm).
  6.  

To adjust the door lock striker, perform the following procedure:



Click image to see an enlarged view

Fig. Fig. 3: Tap the striker once loosened gently with a plastic ended hammer to adjust

  1. Check that the door fit and the door lock linkages are adjusted properly.
  2.  
  3. Slightly loosen the striker mounting screws and tap striker with a hammer until the desired position is obtained.
  4.  
  5. Tighten the striker mounting screws to 19 ft. lbs. (26 Nm).
  6.  

 
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