The upper and lower hinges of the vehicle are similar. Both hinges do not have to be replaced unless damage warrants replacement of both. The hinges are similar on left and right sides of the vehicle. These replacement procedures apply to all.

1. Remove all of the related panels and components.
2. Remove the sealer surrounding the hinge (1).



3. Scribe the location of the hinge (1).



4. Hand-sand the existing hinge (1) with 100 grit sandpaper to locate the 4 weld locations.




Important: Punch the center of the weld so that as much of the weld as possible is removed during drilling.

5. Center punch each weld location  (1).




Important: Drill through the hinge base only (1). Do not drill through the mating surface (2).

6. Remove the hinge tab (3) before drilling, if necessary.



7. At each punch location, drill a 3 mm (1/8 in) pilot hole (1).
8. Using the pilot hole as a guide, drill through the hinge base using a 19 mm (3/4 in) rotabroach hole saw or equivalent (2).




Important: If necessary, use a chisel to separate the hinge from the mating surface.

9. Remove the hinge.



10. Remove the remaining weld from the mating surface to ensure a flush fit of the service hinge.

1. Position the service hinge (1) within the scribe marks (2) on the door (3).
2. Mark each hole location on the door according to the service hinge (4).



3. Drill a 3 mm (1/8 in) pilot hole at each location (1).
4. Drill a 13 mm (1/2 in) hole at each pilot hole location (2).
5. Clean and prepare all bare-metal surfaces.

Important: Prior to refinishing, refer to the publication GM 4901M-2001 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

6. Apply an anti-corrosion primer.

Notice: Refer to Fastener Notice in the Preface section.




7. Align the hinge (1) and the backing plate (2) with the holes in the door (3).

Tighten
Tighten the 4 bolts to 25 N·m (18 lb ft).

8. Hand tighten all of the 4 supplied bolts (4).
9. Align the hinge.
10. Torque all of the 4 bolts.



11. Clean and prepare all bare-metal surfaces.
12. Apply a full-bodied caulk around the service hinge.
13. Refinish as necessary.
14. Install and align all of the related panels and components.