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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1263 (Body Rear End) >> Repair Instructions >> Hinge Replacement - Rear Door >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Refer to FASTENER NOTICE in GM Vehicles Cautions & Notices.
  1. Install the hinge pin bushings.
  2. Apply a medium-bodied sealer to the mating surface of the hinge halves.
  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 in Doors.
  6. Install the tail lamp filler panel.
  7. Install the tail lamp. Refer to TAIL LAMP REPLACEMENT in Lighting Systems.
  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. Ensure that the left door is closed when adjusting the right door.
    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.
    10. Fig 1: Identifying Rear Door Hinge Components
    G02507109Courtesy of GENERAL MOTORS CORP.
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