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Home >> Chevrolet >> 2002 >> Astro Van Passenger, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 825 (Body Rear End) >> Repair Instructions >> Hinge Replacement - Rear Door >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Safari and 2003 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the hinge pin bushings.
  2. Apply a medium-bodied sealer to the mating surface of the hinge halves.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  3. Install the following components to the door and the body frame:
    • Anchor plates
    • Bolts (3)

      Tighten 

      Tighten the bolts to the door and the body frame to 27 N.m (20 lb ft).

    • Hinge halves

      Align the hinge with the previously made mark.

  4. Paint the hinge and the surrounding area.
  5. Install the trim panel. Refer to TRIM PANEL REPLACEMENT - DOOR .
  6. Install the taillamp filler panel.
  7. Install the taillamp. Refer to TAIL LAMP REPLACEMENT .
  8. Install the door to the vehicle. Refer to DOOR REPLACEMENT - REAR (CARGO DOORS)  or DOOR REPLACEMENT - REAR (E54)  .
  9. Adjust the door to fit properly in the door opening frame:
    1. 9.1. Ensure that the left door is closed when adjusting the right door.
    2. 9.2. Do not close the right door completely until a visual check is made in order to determine that the lock assembly is properly engaged to the striker.
      Fig 1: Installing Rear Door Hinge Pins
      G01567332Courtesy of GENERAL MOTORS CORP.
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