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

Removal Procedure

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


    Object Number: 1220664 Size: SH

    Important: In case of the front passenger door, remove the glove box in advance.

  1. Disconnect the negative battery cable.
  2. Disconnect the electrical connector under the instrument panel.

    3. Object Number: 1220668 Size: SH
  3. Remove the fender. Refer to Front Fender Replacement in Body Front End.
  4. Remove the door hinge bolts (1).
  5. Remove the door hold open bolt (2).
  6. Disconnect the body-to-door rubber grommet (4).
  7. Remove the front door assembly (3).

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1220677 Size: SH
  1. Connect the body-to-door rubber grommet.
  2. With the aid of another technician, lightly secure the front door with the bolts.
  3. Adjust the door for proper fit.
  4. Tighten the hinge-to-body bolts.
  5. Install the door hold open link with the bolt.
  6. Install the fender. Refer to Front Fender Replacement in Body Front End.
  7. Connect the electrical connector.
  8. Connect the negative battery cable.
  9. Perform the waterleak test. Refer to Body Waterleak Repair in Waterleaks.
  10. Check for windnoise. Refer to Air/Wind Noise in Air/Wind Noise.