The following procedure requires the use of an1/8in. (3mm) drill bit,1/2in. (13mm) drill bit, a center punch, a cold chisel, a portable body grinder, a putty knife, and a scribing tool.
REMOVAL & INSTALLATION
See Figures 1 and 2
- Refer to the Door, Removal and Installation procedures in this section and remove the door(s), then place the door on a padded workbench.
- Using a putty knife, remove the sealant from the around the edge of the hinge.
- Using a scribing tool, outline the position of the hinge(s) on the door and the body pillar.
- Using a center punch, mark the center position of the hinge-to-door and the hinge-to-body pillar welds.
- Using a 1 / 8 in. (3mm) bit, drill a pilot hole completely through each weld.
When drilling the holes through the hinge welds, DO NOT drill through the door or the body pillar.
- Using a 1 / 2 in. (13mm) bit, drill a hole through the hinge base, following the 1 / 8 in. (3mm) pilot hole.
- Using a cold chisel and a hammer, separate the hinge from the door and/or the body pillar. Using a portable grinder, clean off any welds remaining on the door or the body pillar.
To fasten the replacement hinge(s) to the door and/or body pillar, perform the following procedures:
- Align the replacement hinge, with the scribe lines, previously made.
- Using a center punch and the new hinge as a template, mark the location of each bolt hole.
- Using a 1 / 2 in. (13mm) bit, drill holes (using the center marks) through the door and body pillar.
- If the upper body side hinge is to be replaced, remove the instrument panel fasteners, pull the panel outwards and support it.
- Use medium body sealant (apply it to the hinge-to-door or body pillar surface), the hinge-to-door/body pillar bolts and tapped anchor plate.
- Tighten the hinge-to-door/body pillar bolts to 20 ft. lbs. (27 Nm).
- Apply paint to the hinge and the surrounding area.
See Figures 3, 4 and 5
The1/2in. (13mm) drill hinge holes provide for some adjustment.
- Loosen, adjust, then tighten the hinge-to-door/body pillar bolts; close the door, then check the door gap, it should be 4-6mm between the door and the door frame.
- With the door closed, it should be flush, plus or minus 1.0mm, with the body; if not, enlarge the striker hole.