GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 ION 🢒 Body Repair 🢒 Bolted Exterior Body Panels and Closures 🢒 Front Side Door Replacement

Removal Procedure

    Object Number: 875774 Size: SH
  1. Remove the front carpet retainer. Refer to Front Carpet Retainer Replacement .
  2. Disconnect the front door wiring harness from the main body wiring harness at the front door pillar.
  3. Pull the rubber wiring conduit out of the hinge pillar.
  4. Pull the wiring harness out through the opening in the front door body pillar.

    5. Object Number: 874890 Size: SH
  5. Remove the front door check link bolt.

    6. Object Number: 876125 Size: SH
  6. Remove the front door hinge bolts.
  7. With an assistant, remove the front door.

Disassembly Procedure
  1. Remove the outside panel. Refer to Front Side Door Outer Panel Replacement .
  2. Remove the water deflector. Refer to Front Side Door Water Deflector Replacement .
  3. Remove the door speaker. Refer to Radio Front Side Door Speaker Replacement .
  4. Remove the outside handle pivot. Refer to Door Outside Handle Pivot Replacement .
  5. Remove the lock cylinder. Refer to Door Lock Cylinder Replacement .
  6. Remove the window. Refer to Front Side Door Window Replacement .
  7. Remove the window regulator. Refer to Front Side Door Window Regulator Replacement .
  8. Remove the run channel weatherstrip from the door.
  9. Remove the door check link. Refer to Front Side Door Check Strap Replacement .
  10. Remove the door frame applique. Refer to Front Door Frame Applique Replacement or to Rear Door Frame Applique Replacement .
  11. Remove the outer panel insulator from the door. Refer to Front Side Door Insulator Replacement .
  12. Remove the lock assembly. Refer to Front Side Door Lock Replacement .
  13. Remove the rubber conduit from the front door body pillar.
  14. Remove the door hinges. Refer to Front Side Door Hinge Replacement .
  15. Remove the window run channel. Refer to Door Window Channel Replacement .

Assembly Procedure
  1. Install the window run channel. Refer to Door Window Channel Replacement .
  2. Install the door hinges. Refer to Front Side Door Hinge Replacement ..
  3. Connect the rubber conduit to the front door body pillar.
  4. Install the lock assembly. Refer to Front Side Door Lock Replacement .
  5. Install the outer panel insulator to the door. Refer to Front Side Door Insulator Replacement .
  6. Install the door frame applique. Refer to Front Door Frame Applique Replacement or to Rear Door Frame Applique Replacement .
  7. Install the door check link. Refer to Front Side Door Check Strap Replacement .
  8. Install the run channel weatherstrip to the door.
  9. Install the window regulator. Refer to Front Side Door Window Regulator Replacement .
  10. Install the window. Refer to Front Side Door Window Replacement .
  11. Install the lock cylinder. Refer to Door Lock Cylinder Replacement .
  12. Install the outside handle pivot. Refer to Door Outside Handle Pivot Replacement .
  13. Install the door speaker. Refer to Radio Front Side Door Speaker Replacement .
  14. Install the water deflector. Refer to Front Side Door Water Deflector Replacement .
  15. Install the outside panel. Refer to Front Side Door Outer Panel Replacement .

Installation Procedure

    Object Number: 874890 Size: SH
  1. With an assistant, position the door to the door hinges.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 876125 Size: SH
  2. Install the front door hinge bolts.

    3. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  3. Install the front door check link bolt.

    4. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 875774 Size: SH
  4. Route the wiring harness through the opening in the front door body pillar.
  5. Connect the wiring harness to the main body harness at the front door body pillar.
  6. Install the front carpet retainer. Refer to Front Carpet Retainer Replacement .