4-160. DOOR REPLACEMENT.
This task covers:
General Mechanics Tool Kit
Door Hinge Bolt Wrench (J-22585-01)
Curb Side Door (15593229)
Striker Bolt Wrench (J-23457-A)
Street Side Door (15593230)
General Safety Instructions
Transmission in (N) neutral.
Parking brake and micro-brakelock set.
Mark the position of the hinges (1) and (2)
on the door (3).
Remove the three hinge to door bolts (4)
from the lower hinge.
While the door is being supported, remove
the three hinge to door bolts (5) from the
Remove the door (3).
Position and line up the door (3) with the
hinges (1) and (2) and support it in that
Install the three upper hinge attaching bolts
(5) and torque to 23 ft-lbs (30 N-m).
Install the three lower hinge attaching bolts
(4) and torque to 23 ft-lbs (30 N.m).
Loosen door hinges slightly and adjust the
door, using the wrench to obtain a gap of
0.24 inch ± 0.09 inch (6mm ± 2mm)
between the rocker panel (6) and the door
Adjust the gap between the door (3) and
roof panel (7) to 0.19 inch ± 0.09 inch (5mm