Service Procedure - Front Door Hinge Replacement
SERVICE PROCEDURENOTICE:
THESE PROCEDURES DIFFER FROM PREVIOUS HINGE REPLACEMENT METHODS BECAUSE:
a. Doors remain on vehicle.
b. Access to both front door hinges is made through front wheelhouse area.
c. Hinges come pre-primed and ONLY REAR DOOR HINGES are to be painted using a 5 oz. spray can of appropriate color obtained from GMSPO or a local supplier.
NOTICE:
IN ORDER TO MINIMIZE DOOR REALIGNMENT, DO NOT REMOVE BOTH DOOR HINGES AT THE SAME TIME. DO EACH HINGE SEPARATELY AND, IF BROKEN HINGES ARE NOTED DURING VEHICLE WRITE-UP, REPLACE BROKEN HINGES FIRST.
1. Place vehicle on hoist.
2. Obtain hinges for all doors and (for Corsica model vehicles) correct 5 oz. can of spray paint to match vehicle color.
3. On Corsica model vehicles, Scuff sand and paint REAR DOOR HINGES ONLY using proper color. While allowing painted hinges to dry, perform front door hinge replacement.
FRONT DOOR HINGE REPLACEMENT
4. Using proper lift points, raise vehicle to half up position (until wheel/tire chest high).
NOTICE:
MAKE SURE THAT DOORS ARE FULLY CLOSED (FIRMLY LATCHED ONTO LOCK STRIKER) AND ARE NOT LOCKED.
5. Using two pieces of masking tape, place one piece to bridge gap between door and rocker panel and second piece to bridge gap between door and quarter panel or rear door to act as reference points for door alignment (see illustration).
6. Cut tape at gap area using a utility knife or other suitable tool.
7. Remove front tire and wheel assembly.
8. Using a pin punch, or awl and hammer, and starting at rear of front wheelhouse liner, punch out center mandrels from last five (5) plastic attaching rivets.
9. Remove attaching rivets (not to be reused).
10. Remove remaining screw attachments and position liner forward of front suspension assembly.
11. Remove insulator cover attachments and insulator cover (located between fender and hinge pillar).
12. Clean hinge mounting surfaces on door and body with rag and mark hinge locations on body surfaces with grease pencil or other suitable marker.
NOTICE:
IF A BROKEN HINGE WAS NOTED DURING WRITE-UP, IT SHOULD BE REPLACED BEFORE ANY OTHER HINGE IS REPLACED.
13. Remove hinge attaching fasteners and hinge from vehicle.
14. Install new hinge within previously marked locations using new fasteners and lightly tighten fasteners.
15. Repeat steps 13 and 14 for remaining hinge.
16. Repeat steps 5 through 15 for remaining front door.
17. Install both tire/wheel assemblies to vehicle and lower vehicle to ground level.
18. Inspect edges of tape on door and with aid of a helper, align door as necessary.
19. Raise vehicle to previous position and remove tire/wheel assemblies.
20. Tighten and torque hinge attachments to 20-28 N-m (15 to 20 lb.ft.)
21. Reinstall insulator cover between fenders and hinge pillars.
22. Reposition and install wheelhouse liners using rivets provided and original screws.
NOTICE:
THE PLASTIC RIVETS USED TO RETAIN WHEELHOUSE LINERS TO FENDER FLANGES REQUIRE UNIQUE PLASTIC RIVET INSTALLING TOOLS (LONGER DRAW OR PULL TO SET PLASTIC MANDREL). THESE TYPE TOOLS ARE COMMON TO MOST BODY REPAIR SHOPS AND ARE AVAILABLE FROM VARIOUS SOURCES SUCH AS BODY/PAINT SHOP SUPPLIERS OR LOCAL HAND TOOL DISTRIBUTORS.
23. Reinstall tire and wheel assembly.
24. Carefully remove reference tape from door, rocker and quarter. For Beretta model vehicles, this completes the repairs necessary for this special policy. For Corsica model vehicles, proceed to "Rear Door Hinge Replacement" procedure.