GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Aveo 🢒 Body 🢒 Doors 🢒 Front Side Door Replacement

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1248289 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the door hold open link. Refer to Door Check Link Replacement .
  3. Remove the body-to-door rubber grommet and the electrical wires.
  4. With the aid of another technician, remove the bolts and the front door.

    5. Object Number: 1248290 Size: SH
  5. Disconnect the body-to-door rubber grommet and the electrical connector.

Installation Procedure

    Object Number: 1248290 Size: SH
  1. Connect the electrical connector and the body-to-door rubber grommet.

    2. Object Number: 1248289 Size: SH
  2. With the aid of another technician, lightly secure the front door with the bolts.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Adjust the door for proper fit.

    4. Tighten

        • Tighten the door hinge-to-body bolts to 35 N·m (26 lb ft).
        • Tighten the door hinge-to-door bolts to 15 N·m (11 lb ft).
  4. Install the door hold open link. Refer to Door Check Link Replacement .
  5. Connect the negative battery cable.
  6. Perform the waterleak test. Refer to Waterleak Diagnosis in Waterleaks.
  7. Check for windnoise. Refer to Air/Wind Noise in Air Wind Noise.