Front Door Hinge: Service and Repair

REMOVAL PROCEDURE




1. Remove the door from the body.
2. Remove the excess sealer surrounding the hinge.
3. Scribe the location of the existing hinges on the body pillar and the door.
4. Center punch each of the weld marks on the original hinge, so that all of the weld is removed during the drilling.




5. Drill a 3.0 mm (0.12 in) pilot hole through the welds (5) to a depth that penetrates only the hinge base.
6. Using the smaller hole as a pilot, drill a 13.0 mm (0.51 in) hole only through the hinge base.




7. Drive a chisel between the hinge and the door pillar.
8. In the replacement of the left hinge, complete the following steps:
8.1. Remove the sill plate.
8.2. Lift the kick pad from the retainers in order to remove the kick pad.
8.3. Remove the parking brake assembly.
8.4. Carefully pry away the cowl side panel insulator over the lower access hole.
Set aside the cowl side panel insulator for reuse.
9. In the replacement of the right hinge, complete the following steps.
9.1. Remove the sill plate.
9.2. Lift the kick pad from the retainers in order to remove the kick pad.
9.3. Remove the storage compartment.
9.4. Carefully pry away the cowl side panel insulator over the lower access hole. Set aside the cowl side panel insulator for reuse.

INSTALLATION PROCEDURE




1. Install the bolt-on hinges to the pillar and the door by completing the following steps:
1.1. Position the bolt-on service replacement hinges within the scribe marks made on the body hinge pillar at the time of the removal.
1.2. Center punch each bolt hole location on the body hinge pillar and/or on the door.
1.3. Drill a 13.0 mm (0.51 in) hinge attaching hole in 3 steps in order to assure the proper placement of the hinge.
2. Prepare the surface for the replacement hinges using a file or a similar tool.
3. Coat the mating surfaces of the hinges with a medium-bodied sealer.
4. Install the hinges, the backing plate, the bolts, and the nuts by completing the following steps:
4.1. Align the hinge, the pillar, and/or the door with the holes in the hinge pillar and the door.
4.2. Place the bolts through the hinge, the pillar and/or the door, and the backing plate.




5. Apply sealer around the hinges.

NOTE: Refer to Fastener Notice in Service Precautions.

6. Install the nuts.

Tighten
Tighten the nuts to 35 N.m (26 lb ft).




7. In the replacement of the left side hinges, complete the following steps:
7.1. Install the cowl side panel insulator over the lower access hole.
7.2. Install the parking brake assembly.
7.3. Install the kick pad.
7.4. Install the sill plate.
8. In the replacement of the right side hinges, complete the following steps:
8.1. Install the cowl side panel insulator over the lower access hole.
8.2. Install the glove compartment.
8.3. Install the kick pad.
8.4. Install the sill plate.
9. Install the door to the body.
10. Install the door module panel.
11. Install the trim panel.
12. Adjust the door. Refer to Door Adjustment.