CARAVAN DOOR TRIM REMOVAL (based on a deluxe trim 1994 model) Note: most of this is to get full access inside the door. For some things like the window & mirror switch panel you should go directly to that section which may be much easier. (I suggest arming yourself with double-sided tape or "mastic" sealant that will remain tacky, to re-attach the plastic sheet behind the trim panel, as its attaching mastic tends to go hard and as well you may need more spots from it getting torn.) SCREWS Remove screw visible when inside handle is pulled, to detach its surround. Remove plugs four locations: door horizontal pull large screw, door vertical pull at top, map pocket (two). (Need a slim knife or such tool.) Remove screws those locations. Remove screw at top fwd corner. SWITCH PANEL Pop out switch panel (one spring latch each end) and pull it out to disconnect its two connectors/pull large connector & switch out of panel. See notes below re latches/retention. PANEL LOWER CLIPS Pull trim panel out at bottom progressing to top - panel will remain attached at window. (All but top retention at window are pop out fasteners of typical automotive trim type.) LIGHT ASSEMBLY & HANDLES Disconnect connector to light assembly. You might tilt inner handle surround to push it back through opening, rather than disconnect its connector (door lock switch). PANEL TOP CLIPS Pulling panel out to clear lock knob, force panel upward to clear two retainer brackets at window opening (one aft one fwd, with foam pad to left of each one). (Trim panel hooks over the brackets with a detent bump. Window lower edge seal is part of trim panel.) SPEAKER To get plastic panel off and see into latch area you may need to remove a speaker assembly. MIRROR: Wiring is top connector, a black plastic piece snaps out giving better access to route wiring of replacement mirror. Held by three nuts onto studs in the mirror assembly. 8mm hex flats. (Suggest magnetic wrench or hold fingernail over end of socket to remove without dropping, perhaps from below with black plastic piece out of the way.) Mirror is a complicated assembly. You can see the inside of it by popping the inner end off (visible tab at bottom when folded forward, similar tab well inside). The manual diagnoses heated mirror to the point of saying to replace it but does not detail how. There are two screws under the fragile flexible seal around the mounting but removing those is not enough, perhaps there is a hidden clip. There are two difficult to get at screws partly visible with the mirror removed. Mirror stud pattern 1 11/16 x 2 1/8 x 2 13/16 inches. Surround 2 1/4, 2 5/8, 3 5/16 so approx 1/2" greater (surround matches built-in washers on studs, i.e. corners circular at 1/4" radius). NOTES: Speaker Grill (Infinity) You can leave speaker in place (attached to trim panel with hooks at bottom and snap-studs at top corners). Note that the speaker is attached to door frame with pop rivets. Dust Barrier (Dust barrier weak self-tack adhesive, can see into latch area but difficult to understand and main latch somewhat hidden - might need to remove speaker to get adequate hand access to re and re. (Latch assembly has three screw heads on aft edge of door.) Connector & switch retention Large connector and window switch assembly has key projection one side to fit correctly into the small switch panel - key goes inboard/fwd (the connector latches near two corners do not need undoing to remove from switch panel - retention of switch assembly into panel unkown, seems to be just snap fit). Medium connector has latch one end. Small connector (light) has latch one side. The mirror and power window switch blocks pop out of the panel, carefully - you can see the latches on the sides (you'll have to stick something on one side after unlatching it, otherwise it tends to relatch as you unlatch the other side). The switch blocks can be taken apart, carefully of course, to clean out some of the gunk with toothpick/Q-Tip, and lightly abrade the contacts (it'll take an especially slim point file). The window switch assembly is keyed together by differing ledge heights, the mirror switch obviously fits together only one way, and keying into the panel is obvious if you look at orientation for the user and differing tab widths. Anti-rattle pieces Window anti-rattle snub adjustable centre of window lower sill. Foam block aft lower corner also snubs - foam block fwd lower corner appears not to snub. -------------------------------------------------------------------------------------- Copyright Keith Sketchley 2009.05.17 (1040PST) -------------------------------------------------------------------------------------- BACK in your browser should return you to the page you came here from.