GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Aveo 🢒 Body Repair 🢒 Bolted Exterior Body Panels and Closures 🢒 Front Side Door Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning 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. Caution: Refer to Fastener Caution 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 Test Preparation.
  7. Check for windnoise. Refer to Air/Wind Noise.