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

Removal Procedure

    Object Number: 859285 Size: SH

    Caution: If energy absorber is removed or damaged it must be replaced with a new part. If omitted, the vehicle will not meet federal motor vehicle safety standards (FMVSS), subjecting the retailer to possible civil penalties for making the vehicle inoperative to the FMVSS, and increasing the risk of injury to the vehicle occupants.

  1. Support the door assembly in the full open position.
  2. Mark the outside position of the hinges on the door assembly with a soft marker for installation.
  3. Remove the bolts from the upper and lower hinges at the door attachment locations.

    4. Object Number: 866931 Size: SH
  4. Remove the door assembly from the vehicle.
  5. Remove the quarter outer panels and remove the quarter panel fasteners for access to the hinge bolts.
  6. Mark the position of the hinges on the hinge pillar with a soft marker for installation.
  7. Loosen the hinge alignment cones.
  8. Remove the bolts from the upper and lower hinges at the hinge pillar. Remove the hinges.

Installation Procedure

    Caution: If energy absorber is removed or damaged it must be replaced with a new part. If omitted, the vehicle will not meet federal motor vehicle safety standards (FMVSS), subjecting the retailer to possible civil penalties for making the vehicle inoperative to the FMVSS, and increasing the risk of injury to the vehicle occupants.

    Notice: If locating cone nut is over-torqued, cone shaft will break. Should locating cone break, remove broken cone from hinge pillar and replace with a new hinge.

  1. Align the hinges to the positioning marks on the hinge pillar.

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


    Object Number: 869313 Size: SH
  2. Install the bolts to the hinge at the hinge pillar. Use the Snap-On Flank Drive Torque Adapter P/N FRDHM10 or equivalent and the torque conversion chart to tighten the hinge bolts.

    3. Tighten
    Tighten the rear door hinge-to-body bolts (Coupe) to 28 N·m (21 lb ft).

  3. Tighten the hinge locating cones. Tighten as required using the Snap-On Flank Drive Torque Adapter P/N FRDHM10 or equivalent and the torque conversion chart.

    4. Tighten
    Tighten the door alignment cone nut to 10 N·m (89 lb in).

  4. Support the door assembly in the full open position.
  5. Align the upper and lower hinges to the positioning marks on the door assembly.
  6. Install the bolts to the upper and lower hinges at the door assembly. Tighten as specified.

    7. Tighten
    Tighten the rear door hinge-to-door bolts (Coupe) to 28 N·m (21 lb ft).

  7. With the rear door in the open position, test the operation of the upper and lower door latch mechanisms.
  8. Close the rear door. Check the door and striker alignment.
  9. Close the front door and check the front door striker alignment and operation.
  10. Check the alignment of the front door outer panel to the rear door outer panel.
  11. Test the completed door alignment for windnoise and waterleaks.