My "How To" for lambo doors =) (56k warning), diy and save $500 (u know you want to!) Options

[forkee]

1994-1999 Toyota Celica Lambo Door Installation


Time: 4 hours per door with 2 people.

Tools:
- Metric Socket Bit Set
- Metric Socket Wrenches
- Hammer
- Hacksaw (or electric shears) to cut fender
- Screwdriver
- Allen keys
- Pliers
- Wire cutter
- Electrical wire
- Zip ties
- Various wire connectors (red and blue butt connectors and splices)
- Wire hose cover
- WD-40 or alternate grease for creaky joints.


Preparation:

Inspect all parts. This particular kit (www.extremedoors.com) came with 2 door hinges, 2 shocks, 2 shock boot screws, 2 shock hat loops, 2 shock hat loop rings, 2 shock hat bolts, 7 regular bolts, and 7 washers. Also included was a CD which my computer couldnt read, and confusing instructions with grainy pictures.



Getting started:

1. Open hood and remove the front bumper. Afterwards, take off the fender by unscrewing supporting bolts. You will need to unscrew:
a. Top screw of the nearest headlight.
b. 2 nuts under the nearest headlight.
c. 1 bolt further back under the 2 nuts.
d. Bolts holding the splash guard to the fender.
e. 1 bolt in back of the splash guard behind the fender and closest to the door hinge.
f. 2 bolts holding the fender to the underside of the car.
g. 1 bolt inside the door jam nearest to the top.
h. 3 bolts on top of the fender.

At this point the fender should come out fairly easy. Reach in back and remove the sidemarker bulb housing. Pull the back out first, then ease the front part down (where you removed the 2 nuts) while pulling the headlight toward the front of the car (this is because a peg attached to the light fits into a hole which is part of the fender. This pic shows where “g”, “e”, and “f” (top to bottom) holds the fender onto the car.



Next, you will need to cut the wires (speaker and door locks). To make sure later reconnection is easier, cut the hose and wires in the middle most location. Now you can remove the stock door hinges. There are 2 main ones and 1 small one on the inside of the door jam. 8 bolts hold the main ones, and 2 hold the small one.

- Remove the small hinge, then while holding the door, remove the four bolts connecting the hinges to the door. Remove the door, then 2 remaining hinges held by 2 bolts each. Grab the hinge that looks like the one pictured below for the driver’s side. Attach it to the door.



-Bring the hinge/door assembly to the car. Attach 2 bolts at the bottom and 2 at the top. Do not tighten the bolts all the way yet. You will need to rotate the hinge. Attach the shock assembly and place in the ball joint in the bottom part of the hinge.





- Screw the shock (onto the door part of the hinge) with an Allen key.
-Position the hinge so that the bottom is as far towards the back of the car as possible, and the top is towards the front of the car. Aligning the hinge will be the most difficult because the slightest angle error will result in the door not closing properly. Take time adjusting it until it closes perfectly horizontally when the door is fully down vertically. The bottom 2 pictures show the bolt positions in relation to the hinge. Use a hammer if needed for making slight adjustments.





Now that it is on there, you will need to reconnect the wires going into the door.





Make sure to put the loom cover over everything and zip tie the old rubber pieces to it.





Lastly you will need to cut and/or fold the inside of the fender. Because the hinge opens up in a different position more inside the fender, it will need more clearance. See the previous pics above for how it could be. Put everything back together and you’re all done! (just do the other side now, lol.)







night time pics





This post has been edited by forkee: Feb 15, 2005 - 12:57 AM