GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Spark 🢒 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: 1220664 Size: SH

    Note: 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 door hinge bolts (1).
  4. Remove the door hold open bolt (2).
  5. Disconnect the body-to-door rubber grommet (4).
  6. Remove the front door assembly (3).

Installation Procedure

    Object Number: 1220668 Size: SH
  1. Connect the body-to-door rubber grommet (4).
  2. With the aid of another technician, lightly secure the front door (3) with the bolts.
  3. Adjust the door for proper fit.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the hinge-to-door bolts (1) and tighten to 15 N·m (11 ft lb).
  5. Install the door hold open link with the bolt (2) and tighten to 5 N·m (44 lb in).
  6. Connect the electrical connector.
  7. Connect the negative battery cable.
  8. Perform the waterleak test. Refer to Body Waterleak Repair.
  9. Check for windnoise. Refer to Air/Wind Noise.