Login- Download PDF Manual
-
In. Lbs.
18
30
— — 21
— — 21
21
— — — 21
— — — — — 30
18
24
30
— 20
— 17
25
17
25
—— — — 55
75
— 89
89
— — 80
30
89
— 89
89
89
60
60
— — — — — 15
— 60
— — — — 60N·m 12
25
40
28
10
10
28
28
10
28
10
10
10
11
40
25
32
40
27
23
34
23
34BODY
23 - 14
BODY (Continued) SPECIAL TOOLSBODY
DR
TrimStickC-4755
TorxBitSetC-4794-B
MoldingRemoverC-4829
DR
TAILGATE
23 - 15
TAILGATE
TABLE OF CONTENTS
page
page
CHECK CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16HINGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17RELEASE HANDLE/LATCH REMOTE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17TAILGATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17CHECK CABLE REMOVAL
(1) Open tailgate. (2) Pry lock tab outward to clear stud head on
cargo box (Fig. 1).
(3) Push cable end forward until stud head is in
clearance hole portion of cable end. (4) Separate cable end from stud. (5) Remove screw attaching cable to tailgate. (Fig.
2)
(6) Separate check cable from tailgate.
Fig.2LATCHHANDLE-LATCH
1 - EXTERIOR HANDLE 2 - CONTROL ASSEMBLY 3 - NUTS (2) 4 - TAILGATE 5 - LATCH 6 - CHECK CABLE 7 - CHECK/LATCH BOLT 8 - LATCH BOLT
INSTALLATION
Fig.1TailgateCheck
1 - TAILGATE STRIKER 2 - SCREW DRIVER 3 - TAILGATE CHECK CABLE 4 - LOCK TAB
(1) Position check cable on tailgate. (2) Install bolt attaching small end of cable to tail-
(3) Tighten tailgate check cable bolt to 23 N·m (17
gate.
ft. lbs.).
(4) Position large end of cable onto stud head and
slide downward to secure lock tab.
23 - 16
TAILGATE
COVER REMOVAL
DR
(1) Open the tailgate. (2) Remove the eight screws and remove tailgate
liner, if equipped.
(3) Remove the bolts and remove the cover. (Fig. 3)
Fig.4TAILGATEHINGE
1 - HINGE/PIVOT 2 - TAILGATE PILLAR 3 - CLIP/BUSHING 4 - BOLTS (2)
LATCH REMOVAL
(1) Remove the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
actuator rod for installation.
(3) Disconnect assembly. (Fig. 3)
the actuator rod at
the control
(4) Remove the latch bolt and the check cable bolt.
(5) Remove the latch and actuator rod assembly.
INSTALLATION
(1) Install the latch and actuator rod assembly. (2) Install the latch and the check cable bolts and
tighten to 23 N·m (17 ft. lbs.).
(3) Connect the actuator rod to the control assem-
bly line up the marks made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
Fig.3TAILGATEASSEMBLY
1 - LATCH ASSEMBLY 2 - CONTROL ASSEMBLY 3 - ACTUATOR ROD (2) 4 - COVER 5 - BOLTS (10)
INSTALLATION
(1) Install the cover and install the bolts and
(Fig. 5)
tighten by hand.
(2) Install
the liner and install
the screws,
if
equipped.
HINGE REMOVAL
(1) Remove the tailgate.
(Refer to 23 - BODY/
TAILGATE/TAILGATE - REMOVAL)
(2) Remove the two screws and remove the hinge/
pivot. (Fig. 4)
INSTALLATION
(1) Install the hinge/pivot and install the screws. (2) Tighten the screws to 34 N·m (25 ft. lbs.). (3) Install the tailgate. (Refer to 23 - BODY/TAIL-
GATE/TAILGATE - INSTALLATION)
DR
TAILGATE
23 - 17
LATCH STRIKER REMOVAL
(1) Open tailgate. (2) Using a grease pencil or equivalent, mark out- line of striker on cargo box jamb to aid installation. (3) Using a Torx drive wrench, remove striker and
washer from cargo box.
INSTALLATION
(1) Position striker and washer on jamb using alignment outline as reference and install with Torx drive wrench.
(2) Tighten the striker to 34 N·m (25 ft. lbs.).
RELEASE HANDLE/LATCH REMOTE REMOVAL
(1) Remove the tailgate cover. (Refer to 23 - BODY/
TAILGATE/COVER - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
latch actuator rods for ease of installation.
(3) Disconnect the latch actuator rods. (Fig. 3) (4) Remove the control assembly nuts and remove the control assembly and the exterior handle. (Fig. 5)
Fig.5LATCHHANDLE-LATCH
1 - EXTERIOR HANDLE 2 - CONTROL ASSEMBLY 3 - NUTS (2) 4 - TAILGATE 5 - LATCH 6 - CHECK CABLE 7 - CHECK/LATCH BOLT 8 - LATCH BOLT
INSTALLATION
lbs.).
(1) Install the handle and the control assembly. (2) Install the nuts and tighten to 7 N·m (60 in.
(3) Connect the actuator rods using the marks
made during removal.
(4) Install the cover. (Refer to 23 - BODY/TAIL-
GATE/COVER - INSTALLATION)
TAILGATE REMOVAL
(1) Open the tailgate. (2) Disconnect the tailgate check cables (Fig. 6). (Refer to 23 - BODY/TAILGATE/CHECK CABLE - REMOVAL)
(3) Close tailgate until the notch in the right hand
collar aligns with the pivot pin.
(4) Slip tailgate hinge collar from pivot pins. (5) Slide tailgate to the right and separate left
hand collar from the pivot pin.
(6) Separate tailgate from vehicle.
Fig.6TAILGATEASSEMBLY
1 - LATCH STRIKER 2 - CHECK CABLE BOLT 3 - CHECK CABLE 4 - TAILGATE 5 - HINGE BUSHING
INSTALLATION
(1) Position tailgate collar on left hand pivot pin
and slide tailgate to the left.
(2) Raise tailgate until the notch in the right hand
collar aligns with the pivot pin.
(3) Connect the tailgate check cables. (Refer to 23 - INSTALLA-
BODY/TAILGATE/CHECK CABLE - TION)
23 - 18
DOOR - FRONT
DOOR - FRONT
TABLE OF CONTENTS
page
DR
page
DOOR
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 24
DOOR GLASS
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24EXTERIOR HANDLE
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24GLASS RUN CHANNEL
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25HINGE
WINDOW REGULATOR - POWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25INSIDE HANDLE ACTUATOR
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 23
SIDE VIEW MIRROR FLAG
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the washers, if there were removed pre-
viously, nuts and tighten to 28 N·m (21 ft. lbs.).
(3) Connect the electrical connectors. (4) Adjust the door as necessary. (Refer to 23 -
BODY/DOOR - FRONT/DOOR - ADJUSTMENTS)
DOOR REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the A-pillar. (Fig. 1)
(2) Using a grease pencil or equivalent, mark the outline of the door hinges on the door to aid in instal- lation.
(3) Support the door with a suitable lifting device.
NOTE: The epoxy bonded washers should not be seperated from the hinge. the washers are removed the door may have to be re-adjusted.
If
(4) Remove the nuts and bolts attaching the door
hinges to the door.
DR DOOR (Continued)
DOOR - FRONT
23 - 19
(3) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(4) Tighten the hinge pillar fasteners to 28 N·m
(21 ft. lbs.).
UP/DOWN
NOTE: Up/down door adjustment is done by loosen- ing either the hinge to the hinge pillar fasteners or the hinge to door fasteners and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
NOTE: When the up/down adjustments are done correctly, the top of the door is positioned over flush to the roof. (Refer to 23 - BODY/BODY STRUC- TURE/GAP AND FLUSH - SPECIFICATIONS)
(1) Support the door with a suitable lifting device. (2) Loosen the latch striker bolts. (Refer to 23 -
FRONT/LATCH STRIKER
BODY/DOOR REMOVAL)
(3) Loosen the hinge to door fasteners (Refer to 23
- BODY/DOOR - FRONT/DOOR - REMOVAL) or loosen the hinge to hinge pillar fasteners (Refer to 23
- BODY/DOOR - FRONT/HINGE - REMOVAL).(4) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten the hinge pillar fasteners or the door
to hinges fasteners to 28 N·m (21 ft. lbs.).
(6) Tighten the latch striker bolts. (Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - INSTAL- LATION)
IN/OUT
NOTE: In/out door adjustment is done by loosening the hinge to door fasteners one hinge at a time and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
(1) Support the door with a suitable lifting device. (2) Loosen the latch striker bolts. (Refer to 23 -
FRONT/LATCH STRIKER
BODY/DOOR REMOVAL)
Fig.1FRONTDOOR
1 - NUTS (2) 2 - UPPER HINGE 3 - STUDS 4 - FRONT DOOR 5 - WIRE HARNESS 6 - LOWER HINGE 7 - ELECTRICAL CONNECTORS (2) 8 - BOLTS (2)
ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles with four doors, it is recom- mended that you adjust the rear door before adjust- ing the front door. (Refer to 23 - BODY/DOORS - REAR/DOOR - ADJUSTMENTS) †Door adjustment measurements should be taken from stationary or welded body panels like the roof, rocker or quarter panels. †During adjustment procedures, is recom- mended that all the hinge fasteners be loosened except for the upper most fasteners. Adjustments can be made using the upper bolts to hold the door with final torque of the fasteners occurring after correct door positioning is achieved. †A suitable body sealant should be used when removing or moving the hinges.
it
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by loosening the hinge to the hinge pillar fasteners one hinge at a time and moving the door to the cor- rect position.
(1) Support the door with a suitable lifting device. (2) Loosen the hinge to hinge pillar fasteners. (Refer to 23 - BODY/DOOR - FRONT/HINGE - REMOVAL)
DR
INSTALLATION
(1) Position the glass into the window opening. (2) Engage the glass into the glass run weather-
strip.
lbs.).
(3) Raise the glass within the door opening and
connect the window regulator to the lift plate.
(4) Install the nuts and tighten to 10 N·m (89 in.
(5) Install the inner belt molding. (Refer to 23 - BODY/WEATHERSTRIP/SEALS/FRONT DOOR INNER BELT WEATHERSTRIP - INSTALLATION) (6) Position the front run channel and install the screws. (Refer to 23 - BODY/DOOR - FRONT/GLASS RUN CHANNEL - INSTALLATION)
(7) Remove the window switch from the wire har-
ness, if equipped.
(8) Remove the window handle, if equipped. (9) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
EXTERIOR HANDLE REMOVAL
(1) Remove the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - REMOVAL)
(2) Disconnect the lock switch electrical connector,
if equipped. (Fig. 3)
(3) Disconnect the actuator rods at the handle. (4) Remove the nuts and remove the handle.
INSTALLATION
(1) Install the exterior handle and install the nuts. (2) Connect the actuator rods at the handle (3) Connect the lock switch electrical connector, if
equipped.
(4) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
DOOR - FRONT
23 - 20
DOOR (Continued)(3) Loosen the hinge to door fasteners. (Refer to 23
- BODY/DOOR - FRONT/DOOR - REMOVAL)
(4) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten the door to hinges fasteners to 28 N·m
(21 ft. lbs.).
(6) Tighten the latch striker bolts. (Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - INSTAL- LATION)
DOOR GLASS REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Reinstall the window handle, if equipped. (3) Remove the window switch from the door trim panel and reconnect it to the door wire harness, if equipped.
(4) Raise the window to the position shown and remove the two nuts attaching the glass to the win- dow regulator. (Fig. 2)
(5) Remove the two front run channel screws. (Refer to 23 - BODY/DOOR - FRONT/GLASS RUN CHANNEL - REMOVAL)
(6) Remove the inner belt molding. (Refer to 23 - DOOR
BODY/WEATHERSTRIP/SEALS/FRONT INNER BELT WEATHERSTRIP - REMOVAL)
(7) Disengage the glass from the regulator and
lower into the door.
opening and remove.
(8) Twist the glass forward in the door window
Fig.2DOORGLASSPOSITIONING
1 - SIGHT WINDOW 2 - WIDOW REGULATOR 3 - SIGHT WINDOW 4 - REGULATOR STABILIZER
DR EXTERIOR HANDLE (Continued)
DOOR - FRONT
23 - 21
Fig.3EXTERIORHANDLE
Fig.4FRONTRUNCHANNEL
1 - FRONT GLASS RUN CHANNEL 2 - UPPER SCREW 3 - LOWER SCREW 4 - DOOR PANEL OPENING 5 - RUN CHANNEL MOUNTING SLOTS (2)
1 - EXTERIOR HANDLE 2 - NUTS (2) 3 - ELECTRICAL CONNECTOR 4 - FRONT DOOR 5 - DOOR LATCH ASSEMBLY 6 - LATCH ACTUATOR ROD 7 - LOCK SWITCH WIRE HARNESS 8 - KEY CYLINDER ACTUATOR ROD
GLASS RUN CHANNEL REMOVAL
(1) Raise glass into the full up position. (2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
FRONT RUN CHANNEL
(1) Remove the window regulator. (Refer to 23 - BODY/DOOR - FRONT/WINDOW REGULATOR - REMOVAL)
(2) Loosen the front run channel screws, slide up
and disengage from the door. (Fig. 4)
(3) Separate the glass run weatherstrip from the
channel and remove the front channel.
REAR RUN CHANNEL
(1) On standard cab models, remove the screws
from the side of the door. (Fig. 5)
(2) On quad cab models, remove the lower screw from the side of the door, loosen the upper screw and disengage from the door. (Fig. 6)
(3) Separate the glass run weatherstrip from the
rear channel and remove the channel.
Fig.5REARRUNCHANNEL-QUADCAB
1 - SCREWS 2 - REAR GLASS RUN CHANNEL 3 - DOOR PANEL OPENING
INSTALLATION
FRONT RUN CHANNEL
(1) Install the channel, position the screws in the
door panel slots and slide into place.
(2) Tighten the screws to 10 N·m (89 in. lbs.).
DOOR - FRONT
23 - 22
GLASS RUN CHANNEL (Continued)DR
INSTALLATION
(1) Install the hinges and bolts. (2) Tighten bolts to 28 N·m (21 ft. lbs.). (3) Install the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - INSTALLATION)
INSIDE HANDLE ACTUATOR REMOVAL
(1) Remove the screw and remove the inside han-
dle. (Fig. 7)
(2) Remove the door trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Disconnect the latch actuator rod. (Fig. 8) (4) Remove the nuts and remove the remote han-
dle actuator.
Fig.6REARRUNCHANNEL-STANDARDCAB
1 - LOWER SCREW 2 - DOOR PANEL OPENING 3 - REAR GLASS RUN CHANNEL 4 - UPPER SCREW
(3) Install the window regulator. (Refer to 23 - BODY/DOOR - FRONT/WINDOW REGULATOR - INSTALLATION)
REAR RUN CHANNEL
(1) On quad cab models, install the channel and
slide the upper screw into the slot.
(2) Install the lower screw and tighten both upper
and lower screws to 10 N·m (89 in. lbs.).
(3) On standard cab models, install the channel
and install the screws.
(4) Tighten the screws to 10 N·m (89 in. lbs.).
BOTH CHANNELS
(1) Stuff the glass run weatherstrip into the chan-
nels.
(2) Verify correct window operation. (3) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
the nuts.
HINGE REMOVAL
(1) Remove the door. (Refer to 23 - BODY/DOOR -
FRONT/DOOR - REMOVAL)
(2) Using a grease pencil or equivalent, mark the
hinge location and remove the bolts.
Fig.7INSIDEHANDLEACTUATOR
1 - BOLT 2 - HANDLE 3 - TRIM PANEL OPENING
INSTALLATION
(1) Install the remote handle actuator and install
(2) Tighten the nuts to 10 N·m (89 in. lbs.). (3) Connect the latch actuator rod. (4) Install the door trim panel.
(Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION)
(5) Install the inside handle and install the bolt. (6) Tighten the bolt to 9 N·m (80 in. lbs.).
DR INSIDE HANDLE ACTUATOR (Continued)
DOOR - FRONT
23 - 23
Fig.8REMOTEHANDLEACTUATOR
Fig.9LATCHASSEMBLY
1 - DOOR 2 - ELECTRICAL CONNECTOR 3 - LATCH ASSEMBLY 4 - BOLTS
(2) Insert a 5/32-inch hex-wrench through hole and
into adjustment screw. Loosen screw.
(3) Operate outside handle several times to release
any restriction because of mis-alignment.
(4) Tighten adjustment screw to 3 N·m (30 in.
(5) Test handle for proper operation.
1 - DOOR 2 - LATCH ASSEMBLY 3 - LATCH ACTUATOR ROD 4 - NUTS (2) 5 - HANDLE REMOTE
LATCH REMOVAL
(1) Raise the window to the full up position. (2) Remove the waterdam. (Refer to 23 - BODY/
lbs.).
DOOR - FRONT/WATERDAM - REMOVAL)
(3) Disconnect the actuator rods. (4) Remove the bolts. (Fig. 9) (5) Disconnect the electrical connector and remove
the latch.
INSTALLATION
latch assembly.
lbs.).
(1) Connect the electrical connector and install the
(2) Install the bolts and tighten to 10 N·m (89 in.
(3) Connect the actuator rods. (4) Adjust the latch as needed.
(Refer to 23 -
BODY/DOOR - FRONT/LATCH - ADJUSTMENTS)
(5) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/LATCH - INSTALLATION)
ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 10)
Fig.10LATCHADJUSTMENTSCREW-TYPICAL 1 - DOOR LATCH 2 - MYLAR TAPE 3 - ADJUSTMENT SCREW
23 - 24
DOOR - FRONT
LATCH STRIKER REMOVAL
DR
(1) Using a grease pencil or equivalent, mark the
position of the striker.
(2) Remove the bolts and remove the striker.
INSTALLATION
(1) Install the striker and install the bolts. (2) Tighten the bolts to 28 N·m (21 ft. lbs.). (3) Adjust the striker if needed.
(Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - ADJUST- MENTS)
ADJUSTMENTS
ADJUSTMENT
(1) Using a grease pencil or equivalent, mark the
position of the striker to aid in adjustment.
(2) Loosen the striker bolts. (3) Change the striker position to adjust the rear gap and flush measurement. (Refer to 23 - BODY/ BODY STRUCTURE/GAP AND FLUSH - SPECIFI- CATIONS)
(4) Tighten the bolts to 28 N·m (21 ft. lbs.).
LOCK CYLINDER REMOVAL
(1) Remove the exterior handle.
(Refer to 23 - BODY/DOOR - FRONT/EXTERIOR HANDLE - REMOVAL)
(2) Remove the clip and remove the lock cylinder
lever and switch, if equipped.
(3) Remove the screw and remove the lock cylin-
der. (Fig. 11)
INSTALLATION
(1) Install the lock cylinder and install the screw. (2) Install the lock cylinder switch, if equipped,
lever and retaining clip.
(3) Install
the exterior handle.
(Refer to 23 - BODY/DOOR - FRONT/EXTERIOR HANDLE - INSTALLATION)
Fig.11LOCKCYLINDER
1 - LOCK CYLINDER 2 - EXTERIOR HANDLE 3 - SCREW 4 - LOCK SWITCH WIRE HARNESS
TRIM PANEL REMOVAL
(1) Remove the window crank, if equipped. (Fig.
13)
(2) Remove the interior handle.
(Refer to 23 - BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - REMOVAL)
(3) Remove the screws at the mirror flag and near
the inside handle. (Fig. 12)
CAUTION: Trim panel is attached to the door using hooks molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur.
(4) Lift the trim panel up off the belt seal and attachment hooks and separate the panel from the door slightly.
(5) Disconnect the power window switch electrical
connector, if equipped, and remove the trim panel.
INSTALLATION
(1) Install the window switch into the trim panel,
if equipped.
(2) Position the trim panel onto the lower hooks and connect the power window switch electrical con- nector, if equipped.
(3) Position the remaining trim panel attachment hooks into the door panel and seat the trim panel into the belt seal fully.
DR TRIM PANEL (Continued)
DOOR - FRONT
23 - 25
the waterdam becomes contaminated or dam-
If aged, replace the waterdam.
(1) Remove the inside handle actuator. (Refer to 23
- BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - REMOVAL)(2) Remove the speaker. (Refer to 8 - ELECTRI-
CAL/AUDIO/SPEAKER - REMOVAL)
(3) Separate the waterdam from the inner door
panel and off of the latch linkages.
INSTALLATION
CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. Do not damage the waterdam during removal and installation. If aged, replace the waterdam.
the waterdam becomes contaminated or dam-
(1) Position the wire harness and actuator rods
through the holes in the waterdam.
(2) Secure the waterdam to the inner door panel. (3) Install the speaker. (Refer to 8 - ELECTRICAL/
AUDIO/SPEAKER - INSTALLATION)
(4) Install the inside handle actuator. (Refer to 23 - BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
WINDOW REGULATOR - POWER REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Remove the window switch from the door trim
panel and reconnect it to the door harness.
(3) Raise the window to the position shown and
remove the nuts. (Fig. 14)
(4) Disengage the door glass from the regulator lift
plate and position into the full up position.
(5) Secure the glass in the up position using a
wood wedge or equivalent. (6) Lower the regulator. (7) Remove the stabilizer nuts. (8) Remove the forward regulator bolt and loosen
(9) Slide the regulator up and out of the keyhole
the other two. (Fig. 15)
slots in the door panel. the
(10) Disconnect
remove the regulator.
electrical
connector
and
INSTALLATION
(1) Install the regulator through the door panel
opening and connect the electrical connector.
Fig.12TRIMPANELASSEMBLY
1 - SCREW INSERT (2) 2 - SCREWS (2) 3 - DOOR TRIM PANEL 4 - LOWER SCREWS (3) 5 - ATTACHMENT HOOKS
Fig.13WINDOWCRANKREMOVALTOOL
1 - WINDOW CRANK REMOVAL TOOL 2 - WINDOW CRANK
(4) Install the screws near the inside handle and
at the mirror flag.
(5) Install
the interior handle.
(Refer to 23 - BODY/DOOR - FRONT/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
(6) Install the window crank, if equipped.
WATERDAM REMOVAL
CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. Do not damage the waterdam during removal and installation.
DOOR - FRONT
23 - 26
WINDOW REGULATOR - POWER (Continued)Fig.14DOORGLASSPOSITIONING
1 - SIGHT WINDOW 2 - WIDOW REGULATOR 3 - SIGHT WINDOW 4 - REGULATOR STABILIZER
Fig.15WINDOWREGULATOR-POWER
1 - REGULATOR STABILIZER 2 - INNER DOOR PANEL 3 - STABILIZER NUTS (2) 4 - REGULATOR 5 - FORWARD BOLT 6 - WIRE HARNESS 7 - BOLTS (2)
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the forward bolt and tighten all three to
10 N·m (89 in. lbs.).
DR
install the nuts and
(4) Position the stabilizer,
tighten to 10 N·m (89 in. lbs.).
(5) Raise the regulator to the position shown in
(Fig. 14).
regulator lift plate.
(89 in. lbs.).
the door trim panel.
(6) Remove the glass support and connect to the
(7) Install the glass nuts and tighten to 10 N·m
(8) Disconnect the window switch and install into
(9) Install the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - INSTALLATION)
WINDOW REGULATOR - MANUAL REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(2) Reinstall the window handle and raise the win- dow to the position shown and remove the nuts. (Fig. 14)
(3) Disengage the door glass from the regulator lift
plate and position into the full up position.
(4) Secure the glass in the up position using a
wood wedge or equivalent. (5) Lower the regulator. (6) Remove the stabilizer nuts. (7) Remove the two lower and loosen the two
upper bolts. (Fig. 16)
(8) Slide the regulator up and out of the keyhole
(9) Remove the regulator from the door panel
slot.
opening.
INSTALLATION
inner door panel.
(1) Install the regulator through the hole in the
(2) Position the regulator and slide the upper bolts
into the keyhole slots.
(3) Install the lower two bolts. (4) Tighten the regulator bolts to 10 N·m (89 in.
lbs.).
(5) Position the stabilizer,
install the nuts and
tighten to 10 N·m (89 in. lbs.).
(6) Using the window handle raise the regulator to
the position shown in (Fig. 14).
(7) Remove the glass support and connect to the
regulator lift plate.
(8) Install the glass nuts and tighten to 10 N·m
(9) Remove the window handle and install the
(89 in. lbs.).
waterdam.
DR WINDOW REGULATOR - MANUAL (Continued)
DOOR - FRONT
23 - 27
SIDE VIEW MIRROR FLAG REMOVAL
(1) Remove the door trim panel. (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
CAUTION: Do not use a drill to remove the heat stakes.
(2) Remove the heat stakes using a razor knife or
equivalent.
(3) Release the tabs and remove the mirror flag.
INSTALLATION
NOTE: Clean the excess heat staking off of the studs to aid installation.
(1) Install the new mirror flag over the tabs and
install the screws into the heat stake studs.
(2) Install the door trim panel.
(Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION)
Fig.16WINDOWREGULATOR-MANUAL
1 - DOOR 2 - REGULATOR BOLTS (4) 3 - REGULATOR 4 - STABILIZER NUTS (2)
23 - 28
DOORS - REAR
DOORS - REAR
TABLE OF CONTENTS
page
DR
page
DOOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 28
DOOR GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 32
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
ADJUSTMENTSADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 33
EXTERIOR HANDLE
TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33GLASS RUN CHANNEL
WATERDAM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34HINGE
WINDOW REGULATOR - POWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34INSIDE HANDLE ACTUATOR
WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DOOR REMOVAL
(1) Disconnect the door wire harness electrical con-
nector at the b-pillar. (Fig. 1)
(2) Using a grease pencil or equivalent, mark the outline of the door hinges on the door to aid in instal- lation.
(3) Support the door with a suitable lifting device.
NOTE: The epoxy bonded washers should not be seperated from the hinge. the washers are removed the door may have to be re-adjusted.
If
(4) Remove the nuts and bolts attaching the door
hinges to the door.
INSTALLATION
(1) Support the door with a suitable lifting device
and install the door onto the hinges.
(2) Install the bolts, nuts and washers, if there were removed previously, and tighten to 28 N·m (21
ft. lbs.).(3) Connect the electrical connector. (4) Adjust the door as necessary. (Refer to 23 -
BODY/DOORS - REAR/DOOR - ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
NOTE: For vehicles equipped with four doors, it is recommended that you adjust the rear door before adjusting the front door. †Door adjustment measurements should be taken from stationary or welded body panels like the roof, rocker or quarter panels. †During adjustment procedures, is recom- mended that all the hinge fasteners be loosened except for the upper most fasteners. Adjustments can be made using the upper fasteners to hold the door with final torque of the fasteners occurring after correct door positioning is achieved.
it
DR DOOR (Continued)
DOORS - REAR
23 - 29
the hinge to door fasteners and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
NOTE: When the up/down adjustments are done correctly, the top of the door is positioned over flush to the roof. (Refer to 23 - BODY/BODY STRUC- TURE/GAP AND FLUSH - SPECIFICATIONS)
(1) Support the door with a suitable lifting device. (2) Remove the latch striker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRIKER - REMOVAL)
(3) Loosen the hinge to hinge pillar fasteners (Refer to 23 - BODY/DOORS - REAR/HINGE - REMOVAL) or loosen the hinge to door fasteners (Refer to 23 - BODY/DOORS - REAR/DOOR - REMOVAL).
(4) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten to hinge pillar fasteners or the door to hinges fasteners and fasteners to 28 N·m (21 ft. lbs.). (Refer to 23 - BODY/DOORS - REAR/HINGE - INSTALLATION)
(6) Install the latch striker. (Refer to 23 - BODY/ DOORS - REAR/LATCH STRIKER - INSTALLA- TION)
IN/OUT
NOTE: In/out door adjustment is done by loosening the hinge to door fasteners one hinge at a time and moving the door to the correct position.
NOTE: When adjustment of the door requires the loosening of the door to hinge fasteners, it will be necessary to separate the epoxy bonded washers with a chisel or other suitable tool.
(1) Support the door with a suitable lifting device. (2) Remove the latch striker. (Refer to 23 - BODY/
DOORS - REAR/LATCH STRIKER - REMOVAL)
(3) Loosen the hinge to door fasteners. (Refer to 23
- BODY/DOORS - REAR/DOOR - REMOVAL)
(4) Adjust the front of the door to the correct posi- tion. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(5) Tighten the door to hinges fasteners to 28 N·m
(21 ft. lbs.).
(6) Install the latch striker. (Refer to 23 - BODY/ DOORS - REAR/LATCH STRIKER - INSTALLA- TION)
Fig.1DOORASSEMBLY
1 - NUTS (2) 2 - UPPER HINGE 3 - UPPER STUD 4 - REAR DOOR 5 - WIRE HARNESS 6 - LOWER STUD 7 - LOWER HINGE 8 - ELECTRICAL CONNECTOR 9 - BOLTS (2)
FORE/AFT
NOTE: Fore/aft (lateral) door adjustment is done by loosening the hinge to the hinge pillar fasteners one hinge at a time and moving the door to the cor- rect position.
(1) Support the door with a suitable lifting device. (2) Loosen the hinge to hinge pillar fasteners. (Refer to 23 - BODY/DOORS - REAR/HINGE - REMOVAL)
(3) Adjust the door to the correct position. (Refer to 23 - BODY/BODY STRUCTURE/GAP AND FLUSH - SPECIFICATIONS)
(4) Tighten to hinge pillar fasteners to 28 N·m (21
ft. lbs.). (Refer to 23 - BODY/DOORS - REAR/HINGE - INSTALLATION)NOTE: Use a suitable body sealer on the hinge to body mating surfaces.
UP/DOWN
NOTE: Up/down door adjustment is done by loosen- ing either the hinge to the hinge pillar fasteners or
23 - 30
DOORS - REAR
DOOR GLASS REMOVAL
DR
(1) Remove the glass run channels. (Refer to 23 - BODY/DOORS - REAR/GLASS RUN CHANNEL - REMOVAL)
(2) Remove the glass support and place the glass
into the bottom of the door.
(3) Separate the glass run weatherstrip from the
rear of the window opening.
(4) Remove the inner belt molding. (Refer to 23 - DOOR
BODY/WEATHERSTRIP/SEALS/FRONT INNER BELT WEATHERSTRIP - REMOVAL)
(5) Remove the glass from the window opening.
INSTALLATION
(1) Install the glass through the window opening
and pace the glass into the bottom of the door.
(2) Install the inner belt molding. (Refer to 23 - BODY/WEATHERSTRIP/SEALS/FRONT DOOR INNER BELT WEATHERSTRIP - INSTALLATION) (3) Stuff the glass run weatherstrip into the win-
dow frame.
(4) Secure the glass in the up position using a
wood wedge or equivalent.
(5) Install the glass run channels. (Refer to 23 - BODY/DOORS - REAR/GLASS RUN CHANNEL - INSTALLATION)
EXTERIOR HANDLE REMOVAL
(1) Remove the front glass run channel. (Refer to 23 - BODY/DOORS - REAR/GLASS RUN CHANNEL - REMOVAL)
(2) Disconnect the latch actuator rod. (Fig. 2) (3) Remove the nuts and remove the handle.
INSTALLATION
(1) Install the latch and install the nuts. (2) Connect the latch actuator rod. (3) Install the front glass run channel. (Refer to 23
- BODY/DOORS - REAR/GLASS RUN CHANNEL - INSTALLATION)GLASS RUN CHANNEL REMOVAL
(1) Remove the window regulator. (Refer to 23 - BODY/DOORS - REAR/WINDOW REGULATOR - REMOVAL)
(2) Remove the bottom screws and loosen the top
screws from bolt channels. (Fig. 3) and (Fig. 4)
Fig.2EXTERIORHANDLE
1 - LATCH ACTUATOR ROD 2 - LATCH 3 - NUTS (2)
(3) Slide the channels up to disengage from the
keyhole slots.
(4) Separate the glass run weatherstrip from the
channel and remove the channels.
Fig.3FRONTRUNCHANNEL
1 - BOLTS 2 - FRONT RUN CHANNEL
DR GLASS RUN CHANNEL (Continued)
DOORS - REAR
23 - 31
UPPER HINGE
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door and b-pillar.
(2) Remove the nut and bolt attaching the hinge to
the door.
(3) Remove the three bolts attaching the hinge to
the b-pillar and remove the hinge.
LOWER HINGE
(1) Using a grease pencil or equivalent, mark the
position of the hinge on the door and b-pillar.
(2) Remove the lower b-pillar trim. (Refer to 23 - TRIM -
LOWER
BODY/INTERIOR/B-PILLAR REMOVAL)
(3) Remove the nut and bolt attaching the hinge to
the door.
the b-pillar.
(4) Remove the two bolts attaching the hinge to
(5) From the inside of the vehicle remove the remaining bolt attaching the hinge to the b-pillar and remove the hinge.
INSTALLATION
UPPER HINGE
(1) Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28
N·m (21 ft. lbs.).(2) Install the three hinge to b-pillar bolts and
tighten to 28 N·m (21 ft. lbs.).
(3) Adjust the door if needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
LOWER HINGE
(1) Install the hinge and install the b-pillar bolts. (2) Tighten the bolts to 28 N·m (21 ft. lbs.). (3) Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28
N·m (21 ft. lbs.).(4) Adjust the door if needed. (Refer to 23 - BODY/
DOORS - REAR/DOOR - ADJUSTMENTS)
(5) Install the lower b-pillar trim. (Refer to 23 - TRIM -
LOWER
BODY/INTERIOR/B-PILLAR INSTALLATION)
INSIDE HANDLE ACTUATOR REMOVAL
(1) Remove the screw and remove the inside han-
dle. (Fig. 5)
(2) Remove the door trim panel. (Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - REMOVAL)
(3) Disconnect the latch actuator rod. (Fig. 6) (4) Remove the nuts and remove the remote han-
dle actuator.
Fig.4REARRUNCHANNEL
1 - REAR RUN CHANNEL 2 - SCREW LOCATIONS
INSTALLATION
(1) Position the run channels into the door and
engage the upper screws into the keyhole slots.
(2) Install the lower screws and tighten to 10 N·m
(89 in. lbs.).
lbs.).
nels.
(3) Tighten the upper screws to 10 N·m (89 in.
(4) Stuff the glass run weatherstrip into the chan-
(5) Verify correct window operation. (6) Install the window regulator. (Refer to 23 - BODY/DOORS - REAR/WINDOW REGULATOR - INSTALLATION)
HINGE REMOVAL
NOTE: It is not necessary to remove the door to replace the hinges if they are replaced one at a time.
NOTE: The epoxy coated washers should not be removed from the hinge. the washers are removed the door may have to be re-adjusted.
If
(1) Open the front door
DOORS - REAR
23 - 32
INSIDE HANDLE ACTUATOR (Continued)DR
LATCH REMOVAL
(1) Raise the window to the full up position. (2) Remove the waterdam. (Refer to 23 - BODY/
DOOR - FRONT/WATERDAM - REMOVAL)
(3) Disconnect the actuator rods. (4) Remove the bolts. (Fig. 7) (5) Disconnect the electrical connector and remove
the latch.
Fig.5INSIDEHANDLEACTUATOR
1 - TRIM PANEL OPENING 2 - INSIDE LATCH HANDLE 3 - BOLT
Fig.6REMOTEHANDLEACTUATOR
1 - NUTS (2) 2 - LATCH ACTUATOR ROD 3 - HANDLE REMOTE
INSTALLATION
(1) Install the remote handle actuator and install
the nuts.
(2) Tighten the nuts to 10 N·m (89 in. lbs.). (3) Connect the latch actuator rod. (4) Install the door trim panel.
(Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - INSTALLA- TION)
(5) Install the inside handle and install the bolt. (6) Tighten the bolt to 9 N·m (80 in. lbs.).
Fig.7LATCHASSEMBLY
1 - DOOR 2 - ELECTRICAL CONNECTOR 3 - LATCH ASSEMBLY 4 - BOLTS
INSTALLATION
(1) Connect the electrical connector and install the
(2) Install the bolts and tighten to 10 N·m (89 in.
latch assembly.
lbs.).
(3) Connect the actuator rods. (4) Adjust the latch as needed.
(Refer to 23 -
BODY/DOORS - REAR/LATCH - ADJUSTMENTS)
(5) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
ADJUSTMENTS
ADJUSTMENT
(1) Locate access hole and remove the mylar tape
covering it. (Fig. 8)
DR LATCH (Continued)
DOORS - REAR
23 - 33
(2) Insert a 5/32-inch hex-wrench through hole and
into adjustment screw. Loosen screw.
(3) Operate outside handle several times to release
any restriction because of mis-alignment.
(4) Tighten adjustment screw to 3 N·m (30 in.
lbs.).
(5) Test handle for proper operation.
TRIM PANEL REMOVAL
(1) Remove the window crank, if equipped. (Fig.
(2) Remove the interior handle.
(Refer to 23 - BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - REMOVAL)
(3) Remove the screw near the inside handle. (Fig.
10)
9)
CAUTION: Trim panel is attached to the door using hooks molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur.
(4) Lift the trim panel up off the belt seal and attachment hooks and separate the panel from the door slightly.
(5) Disconnect the power window switch electrical
connector, if equipped, and remove the trim panel.
Fig.9TRIMPANEL
1 - DOOR 2 - ELECTRICAL CONNECTOR 3 - ATTACHMENT HOOKS 4 - SCREW 5 - TRIM PANEL
INSTALLATION
(1) Position the trim panel onto the lower hooks and connect the power window switch electrical con- nector, if equipped.
(2) Position the remaining trim panel attachment hooks into the door panel and seat the trim panel into the belt seal fully.
(3) Install the screw near the inside handle. (4) Install
(Refer to 23 - BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
the interior handle.
(5) Install the window crank, if equipped.
Fig.8LATCHADJUSTMENTSCREW-TYPICAL
1 - DOOR LATCH 2 - MYLAR TAPE 3 - ADJUSTMENT SCREW
LATCH STRIKER REMOVAL
(1) Using a grease pencil or equivalent, mark the
position of the striker.
(2) Remove the bolts and remove the striker.
INSTALLATION
(1) Install the striker and install the bolts. (2) Tighten the bolts to 28 N·m (21 ft. lbs.). (3) Adjust the striker if needed.
(Refer to 23 - BODY/DOOR - FRONT/LATCH STRIKER - ADJUST- MENTS)
ADJUSTMENTS
ADJUSTMENT
(1) Using a grease pencil or equivalent, mark the
position of the striker to aid in adjustment.
(2) Loosen the striker bolts. (3) Change the striker position to adjust the rear gap and flush measurement. (Refer to 23 - BODY/ BODY STRUCTURE/GAP AND FLUSH - SPECIFI- CATIONS)
(4) Tighten the bolts to 28 N·m (21 ft. lbs.).
DOORS - REAR
23 - 34
TRIM PANEL (Continued)DR
(5) Disengage the door glass from the regulator lift
plate and position into the full up position.
(6) Secure the glass in the up position using a
wood wedge or equivalent. (7) Lower the regulator. (8) Disconnect the electrical connector. (Fig. 12) (9) Remove the lower regulator bolt and loosen the
upper two. (Fig. 12)
slots in the door panel.
inner door panel.
(10) Slide the regulator up and out of the keyhole
(11) Remove the regulator through the hole in the
Fig.10WINDOWCRANKREMOVALTOOL
1 - WINDOW CRANK REMOVAL TOOL 2 - WINDOW CRANK
WATERDAM REMOVAL
(1) Remove the inside handle actuator. (Refer to 23
- BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - REMOVAL)(2) Remove the speaker. (Refer to 8 - ELECTRI-
CAL/AUDIO/SPEAKER - REMOVAL)
(3) Separate the waterdam from the inner door
panel and off of the latch linkages.
INSTALLATION
(1) Position the wire harness and actuator rods
through the holes in the waterdam.
(2) Secure the waterdam to the inner door panel. (3) Install the speaker. (Refer to 8 - ELECTRICAL/
AUDIO/SPEAKER - INSTALLATION)
(4) Install the inside handle actuator. (Refer to 23 - BODY/DOORS - REAR/INSIDE HANDLE ACTUA- TOR - INSTALLATION)
WINDOW REGULATOR - POWER REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Remove the window switch from the door trim
panel and reconnect it to the door wire harness.
(3) Raise the window to the position shown and remove the two nuts attaching the glass to the win- dow regulator. (Fig. 11)
(4) Remove the stabilizer nut.
Fig.11GLASSPOSITIONING
1 - SIGHT WINDOW 2 - STABILIZER NUT 3 - GLASS LIFT PLATE
INSTALLATION
(1) Install the regulator through the hole in the
inner door panel.
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the lower regulator bolt and tighten all
three to 10 N·m (89 in. lbs.).
(4) Connect the electrical connector. (5) Position the stabilizer, install tighten to 10 N·m (89 in. lbs.).
the nut and
(6) Raise the regulator to the position shown in
(Fig. 11).
regulator lift plate.
(89 in. lbs.).
the door trim panel.
(7) Remove the glass support and connect to the
(8) Install the glass nuts and tighten to 10 N·m
(9) Disconnect the window switch and install into
(10) Install the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - INSTALLATION)
DR WINDOW REGULATOR - POWER (Continued)
DOORS - REAR
23 - 35
Fig.12WINDOWREGULATORMOTOR
Fig.13WINDOWREGULATOR-MANUAL
1 - REGULATOR BOLTS 2 - REGULATOR MOTOR 3 - ELECTRICAL CONNECTOR.
WINDOW REGULATOR - MANUAL REMOVAL
(1) Remove the waterdam. (Refer to 23 - BODY/
DOORS - REAR/WATERDAM - REMOVAL)
(2) Reinstall the window handle and raise the win- dow to the position shown and remove the nuts. (Fig. 11)
(3) Remove the stabilizer nuts. (Fig. 13) (4) Disengage the door glass from the regulator lift
plate and position into the full up position.
(5) Secure the glass in the up position using a
wood wedge or equivalent. (6) Lower the regulator. (7) Remove the two back regulator bolts and
loosen the front two.
slots in the door panel.
inner door panel.
(8) Slide the regulator up and out of the keyhole
(9) Remove the regulator through the hole in the
1 - DOOR 2 - REGULATOR BOLTS (4) 3 - STABILIZER NUTS (2) 4 - REGULATOR
INSTALLATION
inner door panel.
(1) Install the regulator through the hole in the
(2) Position the regulator bolts into the keyhole
slots and slide into place.
(3) Install the back regulator bolts and tighten all
four to 10 N·m (89 in. lbs.).
(4) Position the stabilizer,
install the nuts and
tighten to 10 N·m (89 in. lbs.).
(5) Using the window handle raise the regulator to
the position shown in (Fig. 11).
(6) Remove the glass support and connect to the
regulator lift plate.
(89 in. lbs.).
the door trim panel.
(7) Install the glass nuts and tighten to 10 N·m
(8) Disconnect the window switch and install into
(9) Using the window handle raise the regulator to the position shown in (Refer to 23 - BODY/DOORS - REAR/WATERDAM - INSTALLATION)
23 - 36
EXTERIOR
EXTERIOR
TABLE OF CONTENTS
page
DR
page
BODY SIDE MOLDINGS
GRILLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40BODY ISOLATORS
GRILLE FRAME
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40CARGO BOX
FRONT WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41CARGO BOX - TIE DOWN
REAR WHEELHOUSE SPLASH SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41COWL GRILLE
SIDE VIEW MIRROR
