Front Doors GM Full Size Vans 1987-1997 Repair Guide

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REMOVAL & INSTALLATION

1987-95 Models

See Figure 1

Fig. 1: Exploded view of the door hinge components - 1987-95 models

1. Remove the door trim panel and disconnect the electrical wiring harness from the door (if equipped).

2. Remove the kick panel (if equipped).

3. Remove the hinge bolt cover plate. Mark the position of the hinges on the door and the door pillar.

4. Support the door and remove the door frame to hinge bolts.

5. Remove the door from the vehicle.

6. Remove the hinge to door bolts and remove the hinges from the door.

To install:

7. Install the door and line up the hinge with the marks made during removal.

8. Install the hinge-to-frame bolts and tighten them to 25 ft. lbs. (33 Nm).

9. Install the hinge bolt cover plate.

10. Install the kick panel and engage the electrical wiring harness (if equipped).

11. Install the door trim panel.

1996-97 Models

See Figure 2

1. Disconnect the negative battery cable.

2. Remove the hinge pillar trim, then tag and disengage the wiring connectors for the door in the pillar.

3. Remove the rubber conduit by pushing it out from the door pillar and disengage the wiring harness from the pillar.

4. Remove the check link from the pillar.

5. Mark the position of the hinges on the door and the door pillar.

6. Remove the lower hinge pin retainer.

7. Use a soft faced mallet and a pair of locking pliers to grasp the pin and drive it from the hinge.

Install a bolt through the lower hinge temporally to hold the door in place until the top hinge is disconnected.

8. Remove the upper hinge pin retainer and the upper hinge pin in the same manner as the lower pin.

9. Remove the bolt inserted to temporarily hold the bottom hinge, then remove the door.

To install:

Fig. 2: Installing the door hinge pin - 1996-97 models

10. Install the door and line up the hinge with the marks made during removal.

11. Install the bolt through the lower hinge temporally to hold the door in place until the top hinge is secured.

12. Install the upper hinge pin with the pointed end up and a new pin retainer.

13. Remove the bolt inserted to temporarily hold the bottom hinge.

14. Install the lower pin with the pointed end down and a new pin retainer.

15. Install the check link, wiring harness and rubber conduit to the pillar.

16. Engage the door electrical connections.

17. Lubricate the hinge pins with clean engine oil.

18. Install the hinge pillar trim and connect the negative battery cable.

ADJUSTMENT

1987-95 Models

See Figure 3, 4, 5, 6 and 7

Fig. 3: Exploded view of the front door adjustment points

There is no adjustment for the 1996-97 models.

Special tool J-29843-9 door striker wrench, or its equivalent is required to perform this procedure.

Fig. 4: Mark the position of the lock striker ...

Fig. 5: ...and loosen the retainers, then adjust the door to its desired position before tightening the retainers

1. Remove the lock striker protector screw.

2. Remove the lock striker protector.

3. Remove the spring.

Fig. 6: Mark the position of the door striker ...

Fig. 7: ... then loosen the retainers and adjust the striker to the desired position

4. Remove the door striker using Tool J-29843-9 or its equivalent.

5. Remove the spacer.

6. Remove the kick panel (if equipped).

7. Remove the hinge bolt cover screw.

8. Remove the hinge bolt cover.

9. Loosen the door hinge bolts as needed to adjust the door. Adjust the door up or down, forward or rearward, and in or out at the door hinges.

10. Adjust the door to obtain a gap of 0.16-0.20 in. (4-4.61mm) between the front door and the roof panel door striker wrench

The gap between the rocker panel and the front door at its base should be 0.23-0.25 in. (5.84mm-6.61mm).

11. Adjust the door to obtain a gap of 0.16 -0.20 in. (4-4.61mm) between the doors rear edge and the rear door pillar.

The gap between the door's front edge and the rear edge of the fender should be 0.16-0.20 in. (4-4.61mm).

To install:

12. Tighten the door hinge bolts that were loosened.

13. Install the hinge-to-frame bolts and tighten them to 25 ft. lbs. (33 Nm).

14. Install the hinge bolt cover plate.

15. Install the kick panel and engage the electrical wiring harness (if equipped).

16. Install the spacer to the door striker using tool J-29843-9 door striker wrench or its equivalent . Tighten the retainers to 45 ft. lbs. (62 Nm).

17. Install the spring, lock striker protector and pin.