GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Express 🢒 Body and Accessories 🢒 Doors 🢒 Intermediate Side Door Hinge Replacement - Body Side

Removal Procedure
  1. Paint the service hinges body color.
  2. For forward most intermediate door (60 door) hinge replacement move the front seat forward, clear of B-pillar.
  3. Remove the door that requires hinge replacement. Refer to Rear Side Door Replacement .
  4. Remove interior trim at pillar. Refer to Upper Pillar Garnish Molding Replacement , Lower Pillar Garnish Molding Replacement , or Center Pillar Upper Garnish Molding Replacement - Right Side .

    5. Object Number: 1875783 Size: SH
  5. Cut the production body side door hinge. Use a reciprocating saw to gain access for drilling.

    6. Object Number: 1875785 Size: SH
  6. Tape around the periphery of the body side hinge to mark the hinge (1) location.

    7. Object Number: 1875786 Size: SH

    Important: For the forward most intermediate door (60 door), move the backing plate rearward 4 mm (0.16 in) before marking the 3-hole pattern.

  7. Place the service backing plate on the production hinge surface and mark the 3-hole pattern.

    8. Object Number: 1875787 Size: SH
  8. Center punch the marked 3-hole pattern.

    9. Object Number: 1875790 Size: SH
  9. Drill pilot holes with a 3 mm (1/8 in) drill bit all the way through the production hinge and body pillar.
  10. Protect the interior of the vehicle and the adjacent door interior from potential metal grindings.
  11. Lightly sand the body side hinge surface to locate the 3 production welds, look for witness mark.
  12. Center punch the 3 production welds for locating drill bit.

    13. Object Number: 1875791 Size: SH
  13. Using the center punch locations, use a 19 mm (3/4 inch) rota-broach to drill out the remainder of the production hinge without drilling through the body side hinge pillar.
  14. Cut the hinge weld nuggets off.
  15. Grind the pillar hinge mating surface flush.
  16. Using the pilot holes drilled to center the drill bit, drill 13 mm (33/64 in) holes through the pillar.

Installation Procedure

    Object Number: 1875793 Size: SH

    Important: Prior to painting, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

  1. Paint the bare surface of the pillar hinge mounting area according to GM refinish specification GM 4901M-D-2000.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the service hinge and backing plate.

    3. Tighten
    Tighten the bolts to 23 N·m (17 lb ft).

  3. Apply clear silicone sealant around the entire edge of the service hinge to prevent water leaks.
  4. Install the door. Refer to Rear Side Door Replacement .
  5. Adjust adjacent front side door striker as necessary to achieve flushness between the two doors. Refer to Rear Side Door Latch Striker Adjustment - Front .
  6. Install interior trim at pillar. Refer to Upper Pillar Garnish Molding Replacement , Lower Pillar Garnish Molding Replacement , or Center Pillar Upper Garnish Molding Replacement - Right Side .