Original thread here: http://panoramic-3d.ru/forums/interio...uator-fix.html
This is an updated thread to the original. Will be more helpful having all the videos (pics coming shortly) in the original post.
Here is the installation process:
$5 Universal Door Lock from Parts Express:
10" of aluminum bar (I get aluminum bars in 8ft x 3/4" x 1/8") (for making a bracket to mount the actuator to, make 90 degree bends with a 1" tab on both ends)
3.5 ft of wire (estimated) (cut in 2 equal lengths)
2 red butt connectors
2 blue bullet connectors (female)
Making the bracket: Cut aluminum bar to a length of 10 inches. I've found a good size of bar is 3/4" wide x 1/8" thick.
Bend up 1" on each end, making an 8" bracket. Drill a hole in the top middle of each tab, these are to mount the bracket to the door panel.
Next place the actuator on the bracket so you can get accurate placement for the holes you need to drill (use a 4mm drill bit, fits right thru the screw holes in the actuator).
Mount the actuator as far back as you can on the bracket, then cut the actuator rod that comes with the kit to a length of 8" (same length as the bracket).
Large long neck phillips head screwdriver (for removing the door panel)
Regular #2 phillips head screwdriver
4mm drill bit (and power drill)
I find a pocket knife is helpful too
Step 1, remove door panel.
The door panel is secured by 3 phillips head bolts, first remove the little cover in the inner door handle area using a pocket knife so you can remove it gently.
Remove the bolt you just revealed.
Next is removing the inner handle cover. Look at the bottom of it, for 03-04's there is a little niche that your key fits into, use your key to pry up the handle cover.
For 05-07's there is no niche, so you will need to use a pocket knife to remove this gently and without damage.
Remove the 2 phillips head bolts you just revealed behind the handle cover. The bottom one is why you need a long neck screwdriver.
Starting from the part of the door panel nearest the car, pull from the bottom corner near the front of the car. The whole panel is secured using universal panel push pins
that just pop out and back in. (if any are brittle and hard, they will break)
Pull the panel all along the bottom until it is just handing from the window ledge, and the lift the panel vertically starting from the side towards the rear of the car.
The panel is off, but still attached to the car in a few ways. First remove the door latch cable and door lock cable from the inner housing.
Next remove the plug for the lower light that will be on because the door is open. I usually use a screwdriver or knife to push in the release button.
Now push out your window controls from inside the door panel, it just pops out. And then unplug it. I also use a screwdriver to push in the release button.
Now the door panel is completely free, lay it somewhere safe, or carefully lean it up against the car, because we will be working with it soon.
Get your large screwdriver (or 10mm socket) to remove the speaker in the door. There are 3 screws holding it in.
Once removed, there is a sticky lining holding the speaker in, and there are 2 plastic tabs holding it in. Carefully pull out the speaker.
I keep the speaker plugged in and let it dangle facing towards the door so that the magnet doesn't stick to the door.
Reach inside (a little bit easier with the window up) the hole the speaker was in, and there is a plastic black conduit.
Reveal a section of wiring. If driver side, there will be 5 wires wrapped in electrical tape. If passenger side there will only be the purple and blue wires we need.
Find the true blue and purple wires (driver side will have a light blue wire as well, leave this alone).
Cut them as far to the rear of the car as you can, you want to work with the end of the wires lead to inside the car.
I find it easier to have the new wires desheathed and with a butt connector and bullet connector on each of the 2 wires you have.
Desheath the blue and purple wires you just cut in order to attach the red butt connectors on the new wire.
Now pop open one of the hole covers to run the wire thru, and replace the speaker.
Now we work with the door panel. Probably best to watch the video than to try to explain it in detail.
Remove the inner door handle housing using the #2 screw driver (3 screws).
With this you drill a hole with your drill leading into the inner door lock switch. Make it about 4mm above the niche that the door lock cable goes thru.
Next you remove the tab that is on the door lock switch. In the video I just use a drill with lateral movement to remove the tab.
Short blade scissors work well too. This is needed to make some space in there for more hardware.
Once you have installed the bracket with the actuator secured to it, inside the plastic splines (better explained in video), then run the rod in actuators eyelit thru
to the newly modified inner door lock housing.
Next get the little mounting bracket and 3 small screws (included in the kit) and put the rod in the bracket and secure it with a screw.
Now bring the panel up to the door and attach the door release, and then we are going to attach the door lock cable.
This can be somewhat difficult, but after you've done it 20 times it's still a PITA.
Put the door lock cable thru the lower part of the bracket and stick the tab into the hole in the switch.
Now secure it with the other 2 little screws, and MAKE SURE IT DOESN'T PULL THE TAB OUT OF THE HOLE!
You will need to reposition this a couple times to make it perfect. Move the switch a few times and watch the tab to make sure it won't ever get pulled out of the hole.
Move the new actuator rod back and forth to make sure it has full motion to lock and unlock, then make sure all the little screws in the small bracket are TIGHT!
If the little screws get loose, it can result in you not being able to lock your car until you get back in the door panel and resecure this bracket.
Hey it's better than not being able to unlock
Now plug the actuator into the wires you connected earlier and grab your key fob and hit lock and unlock a few times to watch it work.
Look at the switch to make sure it locks when you hit lock. If it unlocks when you hit lock, and vice versa, switch around the wires you plugged into the actuator.
Once satisfied with the actuator locking and unlocking the door, plug in the lower light of the door panel, and pull the plug that goes to the window controls thru
it's hole and put the door panel back on the door, and plug the window controls back in place.
Do one last test of the door lock actuator, and then resecure the door panel, and you're done!
Videos of the process: