GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2006 🢒 GTO 🢒 Preface 🢒 Cautions and Notices 🢒 Front Side Door Replacement

Tools Required
    • BO-46832 Door Hinge Sleeve Remover
    • BO-46835 Door Hinge Sleeve Installer

Removal Procedure

    Object Number: 1353632 Size: SH
  1. Remove the grommet (1) from the door wiring harness connector plug (2).
  2. Depress the tabs and gently pull on the wiring harness to withdraw the connector from the body.
  3. Disconnect the connector.
  4. Remove the door check link. Refer to Door Check Link Replacement .

    5. Object Number: 1353635 Size: SH
  5. Remove the hinge pin cap (2) and the hinge plug (3) from the hinge pin (1) on the upper and lower hinges.
  6. With the aid of an assistant, support the door or support the base of the door on a wooden block and a trolley jack.
  7. Using the BO-46832 . Drive the lower and then the upper hinge pivot sleeves from the hinges.
  8. Remove the door from the vehicle.
  9. Remove the trim panel. Refer to Door Trim Panel Replacement .
  10. Remove the water deflector. Refer to Door Water Deflector Replacement .
  11. Remove the door lock assembly. Refer to Door Lock Replacement .
  12. Remove the outside door handle. Refer to Door Outside Handle Replacement .
  13. Remove the window regulator. Refer to Front Side Door Window Regulator Replacement .

    14. Object Number: 1353637 Size: SH
  14. Remove the filler assembly retainer (1) from the rear inner sealing strip filler assembly (2).
  15. Remove the filler assembly (2) from the rear of the door.
  16. Remove the door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement .
  17. Remove the window guide. Refer to Door Window Guide Replacement .
  18. Remove the window channel. Refer to Door Window Channel Replacement .
  19. Remove the door window. Refer to Door Window Replacement .
  20. Remove the door window weather-strip. Refer to Window Weatherstrip Replacement .
  21. Remove the upper door weather-strip. Refer to Front Side Door Upper Auxiliary Weatherstrip Replacement .
  22. Remove the door window reveal molding. Refer to Front Side Door Window Reveal Molding Replacement .
  23. Remove the door mirror. Refer to Outside Rearview Mirror Replacement .
  24. Remove the door speaker. Refer to Radio Front Side Door Speaker Replacement in Entertainment.
  25. Remove the door wire harness. Refer to Door Wiring Harness Replacement .

    26. Object Number: 1353737 Size: SH
  26. Remove the window channel seal (1) from the door panel upper frame.

    27. Object Number: 1353738 Size: SH
  27. Remove the door deadener (1) from the door panel inner.

    28. Object Number: 1353739 Size: SH
  28. Remove the 2 inside door handle rod clips (1), by turning 90 degrees and then removing from the inner door panel.

Installation Procedure

    Object Number: 1353739 Size: SH
  1. Install the 2 inside door handle rod clips (1) to the inner door panel.

    2. Object Number: 1353738 Size: SH
  2. Install the door deadener (1) to the inner door panel.

    3. Object Number: 1353737 Size: SH
  3. Install the window channel seal (1) to the door panel upper frame.
  4. Install the door wire harness. Refer to Door Wiring Harness Replacement .
  5. Install the door speaker. Refer to Radio Front Side Door Speaker Replacement in Entertainment.
  6. Install the door mirror. Refer to Outside Rearview Mirror Replacement .
  7. Install the door window reveal molding. Refer to Front Side Door Window Reveal Molding Replacement .
  8. Install the door upper weather-strip. Refer to Front Side Door Upper Auxiliary Weatherstrip Replacement .
  9. Install the door window weather-strip. Refer to Window Weatherstrip Replacement .
  10. Install the door window. Refer to Door Window Replacement .
  11. Install the window channel. Refer to Door Window Channel Replacement .
  12. Install the window guide. Refer to Door Window Guide Replacement .
  13. Install the door outer belt sealing strip. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement .

    14. Object Number: 1353637 Size: SH
  14. Install the filler assembly (2) to the rear of the door.
  15. Install the filler assembly retainer (1) to the rear inner sealing strip filler assembly (2).
  16. Install the window regulator. Refer to Front Side Door Window Regulator Replacement .
  17. Install the outside door handle. Refer to Door Outside Handle Replacement .
  18. Install the door lock assembly. Refer to Door Lock Replacement .
  19. Lubricate the door hardware and hinge pivot sleeves prior to assembly. Refer to Door Hardware Lubrication .

    20. Object Number: 1353846 Size: SH
  20. With the aid of an assistant, support the door or support the base of the door on a wooden block and a trolley jack and position the door to the vehicle.
  21. Using the BO-46835 and a hammer. Install the hinge pivot sleeves.
  22. Adjust the door and hinges, if necessary. Refer to Front Side Door Adjustment .

    23. Object Number: 1353635 Size: SH
  23. Install the hinge pin cap (2) and the hinge pin plug (3) to the hinge pin (1) on the upper and lower hinges.
  24. Install the door check link. Refer to Door Check Link Replacement .

    25. Object Number: 1353632 Size: SH
  25. Connect the electrical connector.
  26. Install the grommet (1) to the door wiring harness connector plug (2).
  27. Adjust the window, if necessary. Refer to Front Side Door Window Adjustment .
  28. Install the water deflector. Refer to Door Water Deflector Replacement .
  29. Install the door trim panel. Refer to Door Trim Panel Replacement .
  30. Close the door.