GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 ION 🢒 Body 🢒 Doors 🢒 Rear Side Door Replacement

Removal Procedure
  1. Using a small flat-bladed tool, remove the rear door wiring harness electrical conduit from the rear door pillar.
  2. Disconnect the rear door wiring harness electrical connector.

    3. Object Number: 874887 Size: SH
  3. Remove the rear door check link bolt.

    4. Object Number: 878831 Size: SH
  4. Remove the rear door hinge bolts.
  5. With an assistant, remove the rear door.

Disassembly Procedure
  1. Remove the door trim panel. Refer to Rear Side Door Trim Panel Replacement .
  2. Remove the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
  3. Remove the rear door wiring harness.
  4. Remove the rear door lock. Refer to Rear Door Lock Replacement .
  5. Remove the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement .
  6. Remove the rear door outside handle. Refer to Door Outside Handle Pivot Replacement .
  7. Remove the rear door outer panel. Refer to Rear Side Door Outer Panel Replacement .
  8. Remove the rear door hinges. Refer to Rear Side Door Hinge Replacement .
  9. Remove the rear door check link. Refer to Rear Side Door Check Strap Replacement .
  10. Remove the rear door stationary window. Refer to Rear Side Door Stationary Window Replacement .
  11. Remove the rear door applique. Refer to Front Door Frame Applique Replacement or to Rear Door Frame Applique Replacement .

Assembly Procedure
  1. Install the rear door stationary window. Refer to Rear Side Door Stationary Window Replacement .
  2. Install the rear door check link. Refer to Rear Side Door Check Strap Replacement .
  3. Install the rear door hinges. Refer to Rear Side Door Hinge Replacement .
  4. Install the rear door outside handle. Refer to Door Outside Handle Pivot Replacement .
  5. Install the rear door window regulator. Refer to Rear Side Door Window Regulator Replacement .
  6. Install the rear door lock. Refer to Rear Door Lock Replacement .
  7. Install the rear door wiring harness.
  8. Install the rear door outer panel. Refer to Rear Side Door Outer Panel Replacement .
  9. Install the rear door water deflector. Refer to Rear Side Door Water Deflector Replacement .
  10. Install the rear door applique. Refer to Front Door Frame Applique Replacement or to Rear Door Frame Applique Replacement .
  11. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement .

Installation Procedure

    Object Number: 878831 Size: SH
  1. With an assistant, position the rear door to the rear door hinges.

    2. 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.

  2. Install the rear door hinge bolts.

    3. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 874887 Size: SH
  3. Install the rear door check link bolt.

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

  4. Connect the rear door wiring harness electrical conduit.
  5. Press the rear door wiring harness electrical connector into the rear door pillar until fully seated.