Door — removal, installation and adjustment
Warning: The models covered by this manual are equipped with Supplemental Restraint Systems (SRS), more commonly known as airbags. Always disarm the airbag system before working in the vicinity of any airbag system component to avoid the possibility of accidental deployment of the airbag, which could cause personal injury (see Chassis electrical system) Warning: Wear gloves when working inside the door openings to protect against cuts from sharp metal edges.
Note: The door is heavy and somewhat awkward to remove and install — at least two people should perform this procedure.
Removal and installation
1. Lower the window completely in the door, then disconnect the cable from the negative battery terminal (see Engine electrical systems).
2. Open the door all the way and support it from the ground on jacks or blocks covered with rags to prevent damaging the paint.
3. Remove the door trim panel and water- shield (see Door trim panels — removal and installation).
4. Disconnect all electrical connections, ground wires and harness retaining clips from the door.
Note: It is a good idea to label all connections to aid the reassembly process.
5. From the door side, detach the rubber conduit between the body and the door. Pull the wiring harness through the conduit hole and remove it from the door.
6. Remove the door stop strut bolt (see
illustration).
17.6 Remove the bolt retaining the door stop strut
7. Mark around the door hinges with a pen or a scribe to facilitate realignment during reassembly.
Note: On Lexus models, pry the hinge trim cover out using a screwdriver or trim tool.
8. With an assistant holding the door, remove the hinge-to-door bolts (see illustrations) and lift the door off.
17.8a Remove the door hinge bolts with the door supported (bottom hinge bolts indicated , top hinge similar)
17.8b Open the front door to access the rear door hinge-to-body bolts
9. Installation is the reverse of removal.
Adjustment
10. Having proper door-to-body alignment is a critical part of a well-functioning door assembly. First check the door hinge pins for excessive play. Fully open the door and lift up and down on the door without lifting the body. If a door has 1/16-inch or more excessive play, the hinges should be replaced.
11. Door-to-body alignment adjustments are made by loosening the hinge-to-body bolts or hinge-to-door bolts and moving the door. Proper body alignment is achieved when the top of the doors is parallel with the roof section, the front door is flush with the fender, the rear door is flush with the rear quarter panel and the bottom of the doors are aligned with the lower rocker panel. If these goals can’t be reached by adjusting the hinge-to-body or hinge-to-door bolts, body alignment shims may have to be purchased and inserted behind the hinges to achieve correct alignment.
12. To adjust the door-closed position, scribe a line or mark around the striker plate to provide a reference point, then check that the door latch is contacting the center of the latch striker. If not, adjust the up and down position first.
Note: On Lexus models, remove the plastic cover over the striker before making adjustments.
13. Finally, adjust the latch striker sideways position, so that the door panel is flush with the center pillar or rear quarter panel and provides positive engagement with the latch mechanism (see illustration).
17.13 Adjust the door lock striker by loosening the mounting screws and gently tapping the striker in the desired direction
