Front Door: Service and Repair

DOOR

REMOVAL

1. Remove front wheelhouse splash shield. Refer to Front Fender Liner.
2. Disengage clips attaching door harness wire connector to inner fender brace.

Fig. 6:

3. Disconnect positive lock slide on the side of the wire connectors (Fig. 6).
4. Depress lock tab attaching wire connector halves together.
5. Disconnect door harness from body wiring harness.

Fig. 7:

6. Remove bolts attaching door check strap to A-pillar (Fig. 7).
7. Support door on suitable lifting device.

Fig. 8:

8. Remove bolts attaching lower hinge to door end frame (Fig. 8).
9. Steady door on lifting device and remove bolts attaching upper hinge to door end frame.
10. Remove door from vehicle.

INSTALLATION

NOTE: If new hinge pins are to be used, verify that the knurling on the hinge pin is aligned with the knurling on in the door hinge prior to driving in the pin. Also, verify that the hinge pin is fully seated to the door hinge and a new retaining clip is installed.

1. Support door on suitable lifting device.
2. Position door to vehicle. Verify net pierce nubbin is engaged if reusing original hinges. Applies to body half of hinge only.

Fig. 9:

3. Steady door on lifting device and install bolts attaching upper hinge to door end frame. Tighten bolts to 34 N.m (25 ft.lbs.) torque (Fig. 9).
4. Install bolts attaching lower hinge to door end frame. Tighten bolts to 34 N.m (25 ft.lbs.) torque. Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps.

Fig. 10:

5. Install hinge pins (Fig. 10).
6. Install bolts attaching door check strap to A-pillar. Tighten bolts to 12 N.m (105 in.lbs.) torque.
7. Connect door harness into body wiring harness.

Fig. 11:

8. Connect positive lock slide on the side of the wire connectors (Fig. 11).
9. Connect clips attaching door harness wire connector to inner fender brace.
10. Install front wheelhouse splash shield.
11. Verify door operation and alignment. Adjust as necessary.
12. Steady door on lifting device and remove bolts attaching upper hinge to door end frame.
13. Remove door from vehicle.