GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Body and Accessories 🢒 Doors 🢒 Front Side Door Upper Hinge and Lower Hinge Replacement

Removal Procedure

    Object Number: 861198 Size: MF
  1. Mark around the outside of the hinge with a soft marker for installation and place approved support under the door.
  2. Disconnect the check link at the door by removing the bolt.
  3. With the door fully latched on the striker, remove the hinge to door bolts
  4. To remove the lower hinge from the body:
    5. 4.1. Remove the lower fender fasteners.
    4.2. Disconnect the rear half of the fender liner by removing the attaching fasteners.
    4.3. Remove thehinge to body bolts and remove the hinge, one at a time.
  5. To remove the upper hinge from the body:
    6. • Loosen the bolts of the rear half fender.
    • Disconnect the rear half on the wheel liner by removing the attaching fasteners.
    • Twist the rear half of the fender, from the bottom, away from the body to allow the hinge to be removed.

Installation Procedure
  1. Loosely install all of the hinge bolts. Align with the marks made during removal and snug all of the hinge bolts.
  2. Check the fit of the door and adjust as required.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Tighten the hinge to door bolts and then the hinge to body bolts. Apply a sealer to the hinge.

    4. Tighten

        • Tighten the door hinge-to-door bolts to 30 N·m (22 lb in).
        • Tighten the door hinge-to-body bolts to 30 N·m (22 lb in).
  4. Position the fender in place.
  5. Reattach the wheel liner.
  6. Install the fender. Refer to Front Fender Replacement in Body Front End.
  7. Connect the check link to the body bolt.

    8. Tighten
    Tighten the door check link-to-body bolt to 10 N·m (89 lb in).

  8. Remove the support from the door.