Front Door Side Hinge Replacement
Front Door Side Hinge ReplacementREMOVAL PROCEDURE
1. Remove related panels and components.
2. Remove any excess sealer surrounding the hinge and scribe the location of the hinge on the door.
3. Lightly hand-sand the existing body hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door (Fig. 4-31).
IMPORTANT: Punch the center of the weld so that as much of the weld is removed during the drilling as possible.
4. Center punch each of the four weld marks on the original hinge base.
IMPORTANT: Do not drill into the door.
5. Drill through hinge base only at the punch location. Use a 13 mm (1/2 in) rotabroach hole saw, or the equivalent (Fig. 4-32).
6. Remove hinge. If necessary, use a chisel to separate the hinge from the door.
7. Remove all of the remaining weld from the door surface in order to ensure a flush fit of the service hinge.
INSTALLATION PROCEDURE
1. Repair any damage done to door during the drilling or the removal.
2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate.
3. Position the service hinge within the scribe marks on the door.
4. Center punch each hole location on the door according to the service hinge.
5. Drill a 3 mm (1/8 in) pilot hole at each center punch location.
6. Drill a 13 mm (1/2 in) hole at the pilot locations (Fig. 4-33).
IMPORTANT: Prior to refinishing, refer to the publication GM4901M-D-2000 "GM Approved Refinish Materials" for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.
7. Clean and prepare all of the bare metal surfaces.
8. Apply approved anti-corrosion primer.
9. Apply full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal.
10. Align the hinge and the backing plate with the holes in the door (Fig. 4-34).
11. Install the bolts. Tighten the bolts to 25 N.m (20 ft lb).
12. Apply the sealers.
13. Refinish the metal surfaces as necessary.
14. Install and align all of the related panels and the components.