GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Body and Accessories 🢒 Doors 🢒 Front Side Door Replacement

Removal Procedure

    Object Number: 861365 Size: SH
  1. Remove the fender. Refer to Front Fender Replacement in Body Front End.
  2. Remove the door outer panel. Refer to Front Side Door Outer Panel .
  3. Remove the door insulator. Refer to Front Side Door Insulator .
  4. Disconnect the wiring harness connectors.
  5. Disengage the wiring harness grommet from the door structure and remove the harness from the door.
  6. Remove the check link to door structure bolt.

    7. Object Number: 861198 Size: MF
  7. Open the door and support it.
  8. Remove the door hinge to door structure bolts.
  9. Remove the door.

Installation Procedure

    Object Number: 861365 Size: SH
  1. Place the door in the opening and latch to the striker.

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

  2. Install the door hinges with bolts.

    3. Tighten

        • Tighten the door hinge-to-door bolts to 30 N·m (22 lb ft).
        • Tighten the door hinge-to-body bolts to 30 N·m (22 lb ft).
  3. Install the check link to the door with the bolt.

    4. Tighten
    Tighten the door check link-to-door nuts to 25 N·m (19 lb ft).

  4. Connect the wiring harness connectors.
  5. Install the wiring harness grommet to the door structure.
  6. Install the door insulator. Refer to Front Side Door Insulator .
  7. Install the door outer panel. Refer to Front Side Door Outer Panel .
  8. Install the fender. Refer to Front Fender Replacement in Body Front End.
  9. Adjust the door. Refer to Front Side Door Adjustment .