GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Aztek - FWD 🢒 Body 🢒 Doors 🢒 Front Side Door Replacement

Removal Procedure
  1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement .
  2. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
  3. Remove the outside rearview mirror. Refer to Power Mirror Replacement .
  4. Remove the outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement .
  5. Remove the inner belt sealing strip. Refer to Front Side Door Window Belt Inner Sealing Strip Replacement .
  6. Remove the window. Refer to Front Side Door Window Replacement .
  7. Remove the frame applique. Refer to Front Door Frame Applique Replacement .
  8. Remove the window regulator. Refer to Front Side Door Window Regulator Replacement .
  9. Remove the outside door handle. Refer to Front Side Door Outside Handle Replacement .
  10. Remove the inside handle. Refer to Front Side Door Inside Handle Replacement .
  11. Remove the lock. Refer to Front Side Door Lock Replacement .
  12. Remove the window weatherstrip. Refer to Front Side Door Window Weatherstrip Replacement .
  13. Remove the rubber conduit. Refer to Front Side Door Conduit Replacement .
  14. Remove the wiring harness. Refer to Front Side Door Wiring Harness Replacement .
  15. Remove the body side moldings. Refer to Front Side Door Molding Replacement in Exterior Trim.

    16. Object Number: 604574 Size: SH
  16. Support the front door.
  17. Remove the bolt from the upper hinge keeper strap.

    18. Important: Do not dislodge the washer on the lower hinge.

  18. Remove the bolts from the front lower door hinge side.
  19. With an assistant, lift off the front door from the upper hinge.
  20. Remove the side hinge. Refer to Front Side Door Hinge Replacement .

Installation Procedure
  1. Install the front door side hinge. Refer to Front Side Door Hinge Replacement .

    2. Object Number: 604574 Size: SH
  2. With an assistant, lower the front door onto the body side strap of the upper door hinge.

    3. 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.

  3. With an assistant, install the front lower door hinge side bolts.

    4. Tighten
    Tighten the front lower door hinge side bolts to 30 N·m (22 lb ft).

  4. With an assistant, install the keeper strap bolt of the upper door hinge.

    5. Tighten
    Tighten the keeper strap bolt to 10 N·m (89 lb in).

  5. Install the wiring harness. Refer to Front Side Door Wiring Harness Replacement .
  6. Install the rubber conduit. Refer to Front Side Door Conduit Replacement .
  7. Install the body side moldings. Refer to Front Side Door Molding Replacement in Exterior Trim.
  8. Install the window weatherstrip. Refer to Front Side Door Window Weatherstrip Replacement .
  9. Install the lock. Refer to Front Side Door Lock Replacement .
  10. Install the inside door handle. Refer to Front Side Door Inside Handle Replacement .
  11. Install the outside door handle. Refer to Front Side Door Outside Handle Replacement .
  12. Install the window regulator. Refer to Front Side Door Window Regulator Replacement .
  13. Install the frame applique. Refer to Front Door Frame Applique Replacement .
  14. Install the window. Refer to Front Side Door Window Replacement .
  15. Install the outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement .
  16. Install the inner belt sealing strip. Refer to Front Side Door Window Belt Inner Sealing Strip Replacement .
  17. Install the outside rear view mirror. Refer to Power Mirror Replacement .
  18. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
  19. Install the trim panel. Refer to Front Side Door Trim Panel Replacement .
  20. Inspect the front door for proper operation and alignment. Refer to Door Adjustment .