Re: how do I remove a door panel on a Suzuki Aerio
The top of the grab handle pops off and there are two screws underneath as MrEcko wrote. Remove the one screw from the door opener handle and slide the handle and trim forward about 3/8 inch. It will then come out and you can remove the control rod.
Re: how do I remove a door panel on a Suzuki Aerio
There's two pieces to the handle. You have to take a knife and pop pff the top piece and there's screws that you can then screw out the bottom piece. I only know this because my door handle broke today at the place where the screws go in.
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If you have not figured this out yet I should be able to help you. The door panel has 2.5mm allen screws around the outside, remove them, under the pull handle(pry it off) there are 2 philips screws, under the speaker grill(pry it off) there are 4 philips screws. Remove the speaker. Pull the door panel loose, the door handle (the hinged latch release handle) stays on the door frame. Disconnect any wiring to the door panel and set aside.
I believe on this car you will see a plastic sheet covering the metal portion of the door. The easiest way to deal with it is to cut around the pieces where the allen screws went in and the door handle, etc. Just tape the plastic back together when you reinstall.
Once the door panel is off, lower the window to a point that you can see the clamps that hold the window, loosen them and remove the glass.
The regulator is held in place with 4 10 mm bolts, loosen them and bend the regulator out. Remove the motor and swap it over( I believe it is held in place with 3 or 4 t30 screws),
Reassembly is reverse. Close the door and run the window all the way up, hold the switch there to learn the top position.
Height adjustment is done from under the clamps where the glass attaches to the regulator.
First, unscrew the 7 screws holding on the door panel
Next you carefully pry off the tweeter cover that is where the mirror is.Lift the panel up and off of the door . Undo all of the wiring connections except for the window controller.
Open the 2 black rubber view ports (Circled in Yellow) and roll the window up or down until you see the 10mm bolts that hold the window in place.
Loosen, but don’t remove these bolts. Slide the window up, and tape it up, or remove the window and set aside. Next, unplug the door lock plug and move the door panel out of the way.Unscrew the gold 10mm bolts that hold on the metal inner door panel . Also remove the Phillips screw that holds the inner door handle on
Unscrew the small bolt that holds on the lock cylinder that is behind the quarter-sized black cap on the side of the door. Be careful with that little bolt or it will fall into never land .Pull the lock cylinder out and set aside.
Now grasp the door handle, and with your free hand smack your hand holding the handle towards the back of the car. This will release the door handle.Under the door handle is a Phillips screw. Loosen this screw a few turns but don’t remove.
Now undo the 3 black star shaped screws on the door lock.You can now wiggle the inside of the door handle until it comes free. See the tabs that hold it onto the door . When you go to put it back on be sure the tabs get back in the right place.Pull the whole inner door panel and lock mechanism free by wiggling it out of where it sits.
Now you can undo the 3 cables; 1 from the outer door handle yellow mechanism, 1 from the inner door handle mechanism, and 1 from the inner door lock lever.Put on the new lock and put it all back together.
Be sure to test it as you go. I had to turn the lock cable to the inner door lock lever 180 degrees because it was not unlocking properly when I put it back together the first time.
A couple of other notes, there are 2 pieces of plastic that are for the robots to use when putting the door together for the first time. one is a 3 pronged white plastic thing riveted to the inside of the metal door panel. The other is a white plastic thing covering the lock mechanism. You can cut off the fingers and throw the plastic cover away they are both
useless and in the way.When you put it all back together, just go in the opposite order of disassembly. It is a little tricky to get the yellow plastic outer door handle holder into place. Be sure that the little tabs grab the metal of the door or things will not fit together properly.Be sure to test the power window after you put the window back in place. Do not overtighten the bolts on the window, it is glass…..
With a little dexterity, you can do this without removing the door panel. Pop the center tab on the handle with a small flathead. Underneath is the the screw holding the handle. Undo it. Shimmy and loosen the handle to separate it from the door panel. Detach it from the door mechanism transfer bars. Replace.
The problem with removing the door panel are the hidden screws.
Look for area's that have a cover over what will be a screw under the cover.
once you have removed what is only a few screw, and it has been a while since I worked on an 88, So look in the carpet area at the bottom of the door, take an instrument that is thin and push it behind the panel.
the door panel is held on by push type inserts that hold it tight but will release when it is pryed out. The key is to be careful. Sometimes there is a hidden screw and you can find it without breaking the panel if you work your way around and not forcesomething that does not seem to want to move.
Note that there are usually a couple of screws around the door handle so it holds when you pull and there is usually one behind the door opening handel as well.
After you have made sure that all the screws are out there are little christmas tree looking clips that hold the door paned on. Just pull out on the panel, then push up on the panel and release the top.
you will need a t-20 or t-15 torx bit driver to remove 2 screws holding the handle this is all that holds them on, on once you have a replacement handle it is easier to remove 2 lower screws on the door panel and unsnap the door panel to loosen it this will allow space making it easier to reinstall new handle just slide each end into the slot and reinsert 2 screws to not fully tighten until door panel is snapped back in. the panel is held on with clips and can be released using plastic pry tool around door panel edges.
Remove the snap ring from under the inside door handle and plate (a rag around the base of the handle and a left-right tug on the rag may loosen it, or look under it & pry the snap ring off with a small hook tool
Remove the door lock knob bezel; remove the screw & slide it rearward
Remove the door trim; Remove the two clips; slide a thin, flat wide tool under the panel and pry towards you, there are 8 clips to dislodge
Pull the door trim straight up once all of the clips are loosened.