Removal Procedure
- Visually inspect and restore as much of the damage as possible to factory specifications.
- Remove all of the related panels and the components.
- Remove any excess sealer surrounding the hinge.
- Scribe the location of the hinge on the hinge pillar.
- Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar.
- Center punch each of the 4 weld marks on the original hinge.
- Locate and drill out all necessary factory welds in the rear body opening lower filler, using 8 mm (5/16 in) spot weld remover, in order to gain access to the backside of the lower hinge.
- Carefully pry back the filler panel.
- Remove rear body opening lower filler. If necessary, use a chisel in order to separate the filler from the opening.
- Drill through the hinge only at each punch location. Use a 13 mm (1/2 in) rotabroach hole saw or the equivalent.
- If necessary, use a chisel in order to separate the hinge from the pillar.
- Remove the hinge.
- Remove all of the remaining weld from the pillar surface in order to ensure a flush fit of the service hinge.
Important: Use care when removing the filler panel. The filler panel must be reinstalled.
Installation Procedure
- Repair any damage done to the pillar during the drilling or the removal.
- Position the service hinge within the scribe marks on the pillar.
- Center punch each bolt location on the pillar according to the service hinge.
- Drill a 3 mm (1/8 in) pilot hole at each punch location.
- Drill a 13 mm (1/2 in) hole at the pilot locations.
- Clean and prepare all bare metal surfaces.
- Apply an approved anti-corrosion primer.
- Apply full-body caulk to the entire hinge mounting surface.
- Align the hinge with the holes in the pillar.
- Install the hinge fasteners.
- Position the rear body opening lower filler and mig weld in place at factory weld locations.
- Clean and prepare all weld surfaces.
- Refinish the metal surfaces as necessary.
- Align and install all of the related panels and the components.
Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.
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.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
