Installation Instructions

Transcription

1 86-95 Suzuki Diamond Plate Interior Panels (SKU# SIB- DPI) Installation Instructions Suggested Tools: CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. Hammer Center Punch #2 Phillips Screwdriver Electric Hand Drill and Phillips Bit Window Handle Removal Tool (or needle nose pliers) Door Trim Removal Tool

2 Door Handle Case Window Handle Window Handle Trim Step 1 Remove the door handle case by removing (1) phillips screw. Step 2 Remove the window handle and trim (escutcheon). Window Handle Clip Handle Removal tool This picture shows the clip that needs to be removed in order to remove the window handle. Removal Method A Window handle removal with handle removal tool. This Window Handle Removal tool can be purchased with a set of other door trim tools on our web site. Click HERE for more information.

3 Removal Method A Illustrated Removal Method B Window handle removal with a rag. Removal Method B Illustrated Removal Method C Window handle clip removal with pliers (or hook). A new Replacement Window Handle can be purchased on our website. Click HERE for more information.

4 Step 3 Remove the pull handle by removing (2) phillips screws. Step 4 Remove the stopper band by removing (2) phillips screws. Step 5 Separate the door panel from the door using a door trim tool. This Door Trim Removal tool can be purchased with a set of other door trim tools on our web site. Click HERE for more information. Tech Tip A Pop the fasteners loose by placing the tool behind the panel and prying gently at each fastener location. (See Tech Tip C on the next page for fastener locations)

5 The black part stays in the door. Tech Tip B For a clearer view, we are showing proper tool positioning with the door panel removed. Tech Tip C This picture shows the location of each of the (11) trim clips that need to be popped loose. Step 6 Remove the door panel and set it aside. Step 7 Lay the diamond plate door panel on a Glat piece of wood. Position a center punch in the location where you want the screw to be placed. Mark the location with a center punch and hammer. Caution: Do not strike the punch very hard. All that is needed is to make a mark deep enough to keep the self- tapping screw from wandering off mark while drilling.

6 1/4 1/4 Center punched for screw location. Tech Tip 4 of the supplied 6 screws should be placed in the corners, ¼ inch from the edges as shown. The other two screws will be used later. Self Tapping Screw Note: The (4) corner screws can actually be located wherever you think best. However, they cannot be placed in the trim clip locations shown above. 1/4 inch in from the edges worked well for us. For tapping (or making) new threads. For drilling the correct size hole.

7 Step 8 Place the diamond plate panel on a Glat scrap piece of wood. Drill a hole with one of the supplied self- tapping screws. Once the screw begins to thread into the panel stop drilling. Step 9 Position the panel just off the edge of the wood (or work bench) and keep drilling the screw the rest of the way into the panel. Continue drilling until the threads in the aluminum panel strip, allowing the screw to spin freely. Then remove the screw and set it aside to be used later. Step 10 Repeat steps 7 through 9 on the other (3) corners of the door panel. Step 11 Position the panel on the door such that all the panel holes (pull handle, stop strap, window handle, etc.) align with the corresponding holes in the door.

8 Step 12 While holding the door panel in place, install the pull handle. Note: This will help hold the panel in position while installing the self tapping screws in the corners. Step 13 Install the stopper band. Note: If the panel is not in the exact right position, loosen the screws securing the stopper band and pull handle, reposition the panel and retighten the screw. Step 14 Install all 4 corner screws by drilling/ tapping them, through the holes in the door panel, into the door. Step 15 Install the 5th self- tapping screw at the bottom of the panel as shown. This screw will drill and tap through the door panel and door at the same time. Note: This screw can be positioned at your discretion. Just be sure to avoid the trim clips and holes in the door. Refer to Tech Tip C for trim clip locations.

9 Step 16 Install the 6th (and last) self- tapping screw at the top of the panel as shown. Step 17 Install the door handle case. Note: holes. Again, avoid the trim clips and Step 18 Install the window handle trim (escutcheon). Step 19 Install the window handle clip on the window handle.

10 Tech Tip Correct positioning of window handle clip. Tech Tip When installing the handle it should be installed at 45 from true vertical, toward the front of the vehicle with the window rolled all the way up. Step 20 Install the window handle. Congratulations! You have successfully installed a diamond plate door panel. Now on to the second door and other interior panels if you choose. Thanks for purchasing from Low Range Off-Road. Note: The window handle simply snaps into place with moderate pressure.

11 As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at M-F 8am-5pm MST. Thanks again. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 06/21/12 Copyright 2012 Low Range Off-Road, LC All Rights Reserved