Info - Procedure for Aligning Rear Side Replacement Door Using Bolt-on Hinge Kit

Rear side service (replacement) doors for the above models are manufactured with hinges welded in place. The welded hinges do not allow for adjustment, making door alignment difficult. However, due to variations in build, some service doors are not fitting properly without making adjustments.

Bolt-on hinge kits are available to replace the welded hinges and allow proper door alignment. Using the following service procedure(s), remove the welded hinges from the service door and install bolt-on door side hinges, P/N 15025195. If proper door alignment is still not achieved after adjustment with bolt-on door side hinges, remove the body side hinges and install bolt-on body side hinges, P/N 15017902.

1. Remove the door check link attachment bolts from the pillar.
2. Remove the door hinge pin clips.
3. Remove the door hinge pins and remove the door.
4. Remove the door trim panel.
5. Remove the excess sealer surrounding the hinge.
6. Scribe the location of the existing hinges on the door.
7. Lightly sand the existing hinges with 100 grit or finer sandpaper in order to locate each weld attaching the hinge to the door.
8. Center punch each of the weld marks on the original hinges, so that all of the weld is removed during the drilling.

Important: Do not drill into the door. Drill through the hinge only.

9. At each punch location, drill through the hinge base using a 13 mm (0.50 in) rotabroach hole saw or equivalent.
10. Remove the hinges. If necessary, use a chisel to separate the hinges from the door.
11. Remove the entire remaining weld from the door surface in order to obtain a flush fit of the service hinges.
12. Repair any damage done to the door during drilling or removal.
13. Position the service hinges within the scribe marks on the door.
14. Center punch each bolt hole location.
15. Drill a 3 mm (0.12 in) pilot hole at each center punch location.
16. Using the pilot holes as a guide, drill 13 mm (0.50 in) hinge bolt attaching holes.
17. Prepare the surface for the replacement hinges using a file or a similar tool.
18. Apply an approved anti-corrosion primer to all bare metal surfaces. Refer to the GM Refinish Materials Booklet P/N 4901M-D-99 (English) or P/N 4901M-D-F99 (French).
19. Apply a full-bodied caulk to the entire hinge mounting surface in order to obtain a proper seal.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

20. Install the hinge, P/N 15025195, within the scribed location on the door. Use the supplied bolts and backing plate.

Tighten
Tighten the bolts to 24 N·m(18 lb ft).

21. Install the door and the door hinge pins.
22. Adjust the door.
23. Install the door hinge pin clips.
24. Install the door check link attaching bolts to the pillar.

Tighten
Tighten the bolts to 10 N·m(89 lb in).

25. Install the door trim panel.
26. Apply sealer around the hinges.
27. Clean, prepare, and refinish all surfaces as necessary. Refer to the GM Refinish Materials Booklet P/N 4901M-D-99 (English) or P/N 4901M-D-F99 (French).

1. Remove the door check link attaching bolts from the pillar.
2. Remove the door hinge pin clips.
3. Remove the door hinge pins and remove the door.
4. Remove the door trim panel.
5. Remove the jack cover, the jack, and the jack tray.
6. Reposition the rear seat as necessary.
7. Remove the rear window lower garnish molding.
8. Remove the seat belt anchor bolt.
9. Remove the rear screw from the sill trim plate.
10. Remove the quarter panel attaching screws and the quarter panel.
11. Remove the excess sealer surrounding the hinge.
12. Scribe the location of the existing hinges on the pillar.
13. Lightly sand the existing hinges with 100 grit or finer sandpaper in order to locate each weld attaching the hinge to the pillar.
14. Center punch each of the weld marks on the original hinges, so that all of the weld is removed during the drilling.

Important: Do not drill into the pillar. Drill through the hinge only.

15. At each punch location, drill through the hinge base using a 13 mm (0.50 in) rotabroach hole saw or equivalent.
16. Remove the hinges. If necessary, use a chisel to separate the hinges from the pillar.
17. Remove all the remaining weld from the pillar surface in order to obtain a flush fit of the service hinges.
18. Repair any damage done to the pillar during drilling or removal.
19. Position the service hinges within the scribe marks on the pillar.
20. Center punch each bolt hole location.
21. Drill a 3 mm (0.12 in) pilot hole at each center punch location.
22. Using pilot holes as a guide, drill 13 mm (0.50 in) hinge bolt attaching holes.
23. Prepare the surface for the replacement hinges using a file or a similar tool.
24. Apply an approved anti-corrosion primer to all bare metal surfaces. Refer to GM Refinish Materials Booklet P/N 4901M-D-99 (English) or P/N 4901M-D-F99 (French).
25. Apply a full-bodied caulk to the entire hinge mounting surface in order to obtain a proper seal.
26. Install the hinge, P/N 15017902, within the scribed location on the pillar. Use the bolts supplied.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).





Important: Replacement hinges must maintain a gap of 2 mm (0.08 in) between the door side of the hinge and the body side of the hinge bolts.

27. Before installing the door, modify (door side of the hinge) upper and lower extensions (2).
28. Install the door and the door hinge pins.
29. Adjust the door.
30. Install the door hinge pin clips.
31. Install the door check link attaching bolts to the pillar.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

32. Apply sealer around the hinges.
33. Clean, prepare, and refinish all surfaces as necessary. Refer to GM Refinish Materials Booklet P/N 4901M - D - 99 (English) or P/N 4901M - D - F99 (French).
34. Install the quarter panel and the attaching screws.
35. Install the rear screw to the sill trim plate.
36. Install the seat belt anchor bolt.

Tighten
Tighten the bolt to 55 N·m (41 lb ft).

37. Install the rear window lower garnish molding.
38. Install the rear seat.
39. Install the jack tray, the jack, and the jack cover.

Parts are currently available from GMSPO.

For vehicles repaired under warranty, use: