Sliding Side Door GM Full Size Vans 1987-1997 Repair Guide

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REMOVAL & INSTALLATION

1987-95 Models

See Figure 1

Fig. 1: Upper hinge cover mounting - 1987-95 models

1. Remove the upper track cover and the hinge cover.

2. Open the door completely. Mark the position of the roller assembly on the door and remove the upper front roller assembly.

3. Remove the upper rear hinge retainer from the hinge.

4. Lift the upper rear hinge off of the track and remove the hinge.

5. Pivot the door away from the vehicle to disengage the rollers and lower the front roller from the track.

6. Disengage the wiring harness (if equipped).

7. Remove the door from the vehicle.

To install:

8. Engage the wiring harness (if equipped).

9. Insert the lower front roller in the track.

10. Pivot the door away from the vehicle to engage the rollers to the track, then pivot the door towards the vehicle.

11. Insest the upper rear hinge to the upper rear track and lift the hinge roller onto the track.

12. Install the upper rear hinge retainer to the hinge and the upper front roller assembly to the door. Align the roller assembly to the mark made earlier

13. Install the upper rear track cover and the hinge cover.

1996-97 Models

See Figures 2 through 10

Fig. 2: Remove the sliding side door upper roller high trim piece

Fig. 3: Matchmark the position of the hinge; this will prove helpful during installation ...

Fig. 4: ... then loosen the upper hinge bolts

Fig. 5: To ease installation, matchmark the position of the center track hinge:

Fig. 6: Loosen the center hinge retainers

1. Open and support the door, then remove the interior quarter trim panel.

2. Unfasten the center track bumper nut and washer, then remove the bumper.

3. Loosen the center track cap nut and plate, then remove the cap.

4. Remopve the upper and lower roller bolts.

5. With the aid of an assistant, slide the door out the rear of the center track.

Fig. 7: Upper roller bracket mounting - 1996-97 models

Fig. 8: Lower roller bracket mounting - 1996-97 models

Fig. 9: Matchmark the hinge position on the lower hinge ...

Fig. 10: ... then remove the hinge retainers

To install:

6. With the aid of an assistant, slide the door in the rear of the center track.

7. Install the upper and lower roller bolts, then tighten them to 18 ft. lbs. (25 Nm).

8. Install the cap, center track cap nut and plate.

9. Install the bumper, center track bumper nut and washer.

10. Install the interior quarter trim panel.

ADJUSTMENTS

1987-95 Models

UP-AND-DOWN

See Figure 11

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

1. Remove the upper rear hinge cover.

2. Remove the front lock striker.

3. Remove the rear lock striker using tool J-29843-9, or its equivalent.

4. Remove the rear door wedge assembly.

5. Adjust the rear edge of the door to obtain a gap of 0.16-20 in. (4-4.61mm) between the top of the door and the roof side rail. This adjustment should provide a gap of 0.23-0.25 in. (5.84mm-6.61mm) between the bottom of the door and the rocker panel. To accomplish this adjustment, loosen the upper rear hinge to door bolts and align the rear edge of the door up and down. Next, tighten the upper rear hinge to door bolts.

Adjust the front edge of the door by loosening the upper front roller bracket to door bolts and the lower hinge to door bolts. Align the door to obtain the same gap as in step 5, then tighten the lower hinge to door bolts.

Adjust the upper front roller bracket up and down so that the roller is centered in the track. The roller must not touch the top or bottom of the track. Tighten the upper front roller bracket to door bolts.

Install the door wedge assembly and the front and rear lock strikers.

6. Install the upper hinge cover.

Fig. 11: Gap specifications and adjustment points - 1987-95 models

IN-AND-OUT

1. Remove the front lock striker.

2. Loosen the nut retaining the upper front roller to the upper roller bracket.

3. Loosen the lower front roller assembly to roller assembly bracket bolts.

4. Loosen the rear door lock striker.

5. Adjust the door in or out until the surface of the door is flush with the surface of the body.

6. Tighten the rear door lock striker.

7. Tighten the lower front roller assembly to roller assembly bracket bolts.

8. Tighten the nut retaining the upper front roller to the upper roller bracket.

9. Install the front lock striker.

FORWARD-AND-REARWARD

1. Mark the position of the front and rear latch strikers on the body pillars.

2. Remove the front and rear lock strikers.

3. Remove the upper front track cover.

4. Loosen the upper rear hinge striker.

5. Adjust the door forward or rearward to obtain a gap of 0.16-20 in. (4-4.61mm) between the left and right door edge and the door pillars.

6. Tighten the upper rear hinge striker.

7. Install the upper front track cover.

8. Install the front and rear lock strikers at the position previously marked.

FRONT STRIKER

1. Loosen the front latch striker bolts.

2. Slide the door toward the striker.

3. The guide on the door must fit snugly into the rubber lined opening in the striker assembly.

4. Check that the latch fully engages the striker. Add or delete shims behind the striker to accomplish this adjustment.

5. Tighten the striker bolts.

REAR STRIKER

Door striker wrench J-29843-9, or its equivalent, is required to make this adjustment.

1. Loosen the striker using J-29843-9, or its equivalent.

2. Loosen the rear wedge assembly.

3. Center the striker vertically so that the striker properly engages the door lock. Mark the vertical position of the striker.

4. Adjust the striker in or out to align the surface of the door flush with the body surface. Mark the position of the striker.

5. Tighten the striker using tool J-29843-9, or its equivalent.

6. Open the door and apply grease to the striker.

7. Close the door and make an impression of the lock on the striker.

8. Open the door and measure the distance from the rear of the striker head to the impression. The distance should be 0.20-0.30 in. (5-8mm).

9. Adjust the striker by adding or deleting shims. Align the striker to the previously made marks.

10. Tighten the striker using J-29843-9, or its equivalent.

UPPER REAR HINGE

See Figure 12

Fig. 12: Adjustment points and gap specifications on the upper rear hinge - 1987-97 models

1. The lower hinge lever should have a gap of 0.10-0.16 in. (2.54-4.06mm) between the outer edge of the lower hinge lever and the striker latch edge. This adjustment is made by adding an equal amount of shims between the guide block and the hinge assembly, and between the roller and the hinge assembly.

2. Adjust the striker up or down to obtain a gap of 0.06 in. (1.5mm) between the lower edge of the striker plate and the lower edge of the lower hinge lever.

3. Adjust the guide up or down to obtain a gap of 0.02 in. (0.51mm) between the track and the guide.

DOOR HOLD-OPEN CATCH

1. Mark the position of the lower roller assembly to the bracket.

2. Loosen the lower roller assembly bolts.

3. Pivot the lower roller assembly to properly engage the latch striker.

4. Tighten the lower roller assembly bolts.

REAR WEDGE ASSEMBLY

1. Loosen the rear wedge assembly screws.

2. Completely close the door.

3. From inside the vehicle, center the wedge assembly onto the door wedge.

4. Mark the position of the wedge assembly.

5. Open the door, and move the wedge assembly forward ³/₁₆ in. (4.76mm).

6. Tighten the rear wedge assembly screws.

1996-97 Models

UP-AND-DOWN

1. Remove the upper and lower trim.

2. Loosen the bolts retaining the upper and lower front roller to the door and the nuts retaining the lower front roller to the door.

3. Adjust the door up and down until the desired position is achieved.

4. Tighten the nuts retaining the rear roller to the door to 18 ft. lbs. (25 Nm).

5. Tighten the bolts retaining the upper and lower front roller to the door to 18 ft. lbs. (25 Nm).

6. Install the upper and lower trim.

IN-AND-OUT

1. Remove the upper and lower trim.

2. Loosen the bolts retaining the upper and lower front roller to the bracket.

3. Loosen the nuts retaining the rear roller to the bracket.

4. Adjust the door in and out until the desired position is achieved.

5. Tighten the nuts retaining the rear roller to the bracket to 18 ft. lbs. (25 Nm).

6. Tighten the bolts retaining the upper and lower front roller to the bracket to 18 ft. lbs. (25 Nm).

7. Install the upper and lower trim.