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Home >> Saturn >> 2002 >> SC1 Automatic >> Repair and Diagnosis (Single Page) >> Accessories & Equipment >> Anti-Theft Systems >> Door System, Mirror System & Window System -- "S" Series >> Repair Instructions >> Rear Door Adjustment (Coupe) >> Removal Procedure

Removal Procedure

    Fig 1: Rocker Panel Cover & Pushpins
    GM867041Courtesy of GENERAL MOTORS CORP.
  1. Remove the rocker cover. Refer to Rocker Panel Molding Replacement (Sedan/Wagon) or Rocker Panel Molding Replacement (Coupe) in Exterior Trim.
    2. Fig 2: Tape Around Edge Of Quarter Panel
    GM866882Courtesy of GENERAL MOTORS CORP.
  2. Tape around the edge of the quarter panel to prevent damage while aligning the rear door.
  3. Inspect the quarter panel to rear compartment lid alignment and align if necessary. Refer to Rear Compartment Lid Adjustment in Body Rear End.
  4. Remove the upper and lower strikers. Refer to Front Side Door Lock Striker Replacement  and Rear Side Door Lock Striker Adjustment 
    5. Fig 3: Upper Fasteners
    GM866931Courtesy of GENERAL MOTORS CORP.
  5. If necessary, mark the location of the quarter panel. Remove the quarter outer panels and loosen the upper fasteners. Move the quarter panel outboard for access to the hinge fasteners.
    6. Fig 4: Locating Cone Nuts
    GM869313Courtesy of GENERAL MOTORS CORP.
  6. Loosen the locating cone nuts. Grab the flattened end with a 4 mm (5/32 in) wrench or pliers to prevent the cone pin from spinning while loosening the nut.
    7. Fig 5: Adjusting Position Of Rear Door
    GM859357Courtesy of GENERAL MOTORS CORP.
  7. Adjust the position of the rear door using the door-side of hinges for cross-car and up/down, and the body-side hinges for fore/aft and up/down.
    8. NOTE: If locating cone nut is over-torqued, cone shaft will break. Should locating cone break, remove broken cone from hinge pillar and replace with a new hinge.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. When the desired door position is achieved, tighten the locating cones. Grab the flattened end of the stud with 4 mm (5/32 in) wrench or pliers to prevent the cone from spinning while tightening the nut.

    Tighten:  Tighten the door aignment cone nut (Coupe) to 10 N.m (89 lb in).

  9. Use the Snap-On Flank Drive Torque Adapter P/N FRDHM10 or equivalent and the torque conversion chart to tighten the hinge bolts without removing the quarter panel.

    Tighten:  Tighten the rear door-to-body bolts (Coupe) to 28 N.m (21 lb ft).

  10. Install the upper and lower strikers. Refer to Front Side Door Lock Striker Replacement  and Rear Side Door Lock Striker Adjustment .

    Tighten: 

    • Tighten the rear door upper striker-to-body bolts (Coupe) to 32 N.m (24 lb ft).
    • Tighten the rear door lower striker-to-body bolts (Coupe) to 25 N.m (25 lb ft).

  11. Adjust the door strikers. Refer to Rear Compartment Lid Adjustment in Body Rear End.
  12. Install the rocker cover. Refer to Rocker Panel Molding Replacement (Sedan/Wagon) or Rocker Panel Molding Replacement (Coupe) in Exterior Trim.
  13. Test for windnoise and waterleaks.
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