GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Alero Export 🢒 Body and Accessories 🢒 Doors 🢒 Front Side Door Replacement

Removal Procedure
  1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
  2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
  3. Remove the front door speaker. Refer to Radio Front Speaker Replacement in Entertainmnent.
  4. Remove the front door inside handle bezel. Refer to Door Handle Bezel Replacement .
  5. Disconnect the front door electrical connectors from all related components, if equipped.

    6. Object Number: 276401 Size: SH
  6. Remove the door check link. Refer to Door Check Link Replacement .
  7. Support the door.
  8. Mark the position of the door hinge relative to the hinge pillar.
  9. Remove the lower hinge bolts (3) from the hinge pillar.
  10. Remove the upper hinge bolts (2) from the hinge pillar
  11. Remove the front door (1) from the body.

Installation Procedure

    Object Number: 276401 Size: SH
  1. Install the front door (1) to the body.
  2. Snug the upper and lower hinge bolts (4) in order for the door to move.
  3. Carefully close the door (1).
  4. Adjust the door for proper alignment.
  5. Open the door slowly.

    6. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Install the upper hinge bolts (2) to the hinge pillar.

    7. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  7. Install the lower hinge bolts (2) to the hinge pillar.

    8. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  8. Inspect the door for proper alignment.
  9. Install the front door electrical connectors to all related components, if equipped.
  10. Install the front door check link. Refer to Door Check Link Replacement .
  11. Install the front door inside handle. Refer to Rear Side Door Inside Handle Replacement .
  12. Install the front door speaker. Refer to Radio Front Speaker Replacement in Entertainment.

    13. .

  13. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement .
  14. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement .