GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Doors

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. On doors equipped with power operated components proceed as follows:
    1. Remove the door trim panel, insulator pad (if so equipped), and the inner panel water deflector.
    2.  
    3. Disconnect the wiring components inside the door.
    4.  
    5. Remove the rubber conduit from the door, then remove the wiring harness from the door through the conduit access hole.

      Click image to see an enlarged view

      Fig. Fig. 1: You can use this tool to remove the spring



      Click image to see an enlarged view

      Fig. Fig. 2: View of the door hinge assembly - 1994 vehicle shown

    6.  

  2.  
  3. Tape the area (on the door pillar and body pillar) above the lower hinge with fabric tape.
  4.  


CAUTION
Before performing the following step, cover the spring with a towel to prevent the spring from flying out and possibly causing personal injury!

  1. Insert a suitable, long, flat bladed tool under the pivot point of the hold-open link and over top of the spring. The tool should be positioned so as not to apply pressure to the hold-open link. Cover the spring with a shop cloth and lift the tool to disengage the spring. The spring can also be removed by using tool J-28625, or equivalent, door hinge spring compressor tool. The tool is stamped right side and left side. For all the J-cars the tool stamped, "left side" is used to service the right side hinge spring. The tool stamped, "right side" is used to service the left hand hinge spring.
    1. Install the two jaws of the tool over the spring. The jaw with the slots slides over spring at the hold-open link. The jaw with the hole fits over the spring at the bubble on the door hinge pillar.
    2.  
    3. Install the bolt to the jaws of the tool and tighten to compress the spring.
    4.  
    5. Remove the tool and spring from the door hinge assembly. Do not remove the spring from the tool.
    6.  

  2.  
  3. When removing the hinge pin, save the "barrel" clips as follows:
    1. Using two, suitable, flat bladed tools, spread the clip enough to move the clip above the recess toward the pointed end of the pin.
    2.  
    3. As the pin is removed, the clip will ride the shank of the pin and fall free.
    4.  
    5. Reinstall the clips onto the pins before installing the door.
    6.  

  4.  
  5. With the aid of a helper to support the door, remove the lower hinge pin, using a soft headed hammer and locking type pliers. The helper can aid in removing the hinge pin by raising and lowering the rear of the door.
  6.  
  7. Insert the bolt into the hole of the lower hinge to maintain door attachment during upper hinge pin removal.
  8.  
  9. Remove the upper hinge pin in the same manner as the lower. Remove the bolt from the lower hinge and remove the door from the body.
  10.  

To install:

Before installing the door, replace the hinge pin clips or reuse the old clips as explained in the removal procedure.

  1. With the aid of a helper, position the door and insert a bolt in the lower hinge hole.
  2.  
  3. The upper hinge pin is inserted with the pointed end up. The lower hinge pin is inserted with the pointed end down. With the door in the full open position, install the upper hinge pin using locking-type pliers and a soft headed hammer. Use a drift punch and hammer to complete pin installation.
  4.  
  5. Remove the screw from the lower hinge and install the lower hinge pin. The use of the special tool J-28625 or equivalent is the recommended method for installing the hinge spring.
  6.  


WARNING
If the spring is installed before installing the upper hinge pin, damage to the hinge bushings may result!

  1. If the spring was removed using a long, flat bladed tool, install the spring as follows:
    1. Place the spring in tool J-28625 or equivalent.
    2.  
    3. Place the tool and spring in a bench vise.
    4.  
    5. Compress the tool in a vise and install the bolt until the spring is fully compressed.
    6.  
    7. Remove the tool with the compressed spring from the vise and install in the proper position in the door lower hinge. The slot in the jaw of the tool fits over the hold-open link. The hole in the other jaw fits over the bubble.
    8.  
    9. Remove the bolt from the tool to install the spring.
    10.  
    11. Remove the tool from the door hinge. (The tool will fall out in three pieces). Cycle the door to check spring operation.
    12.  

  2.  
  3. If tool J-28625 or equivalent was used to remove the spring, follow Steps d, e, and f above to install the spring.
  4.  
  5. Remove the tape from the door and body pillars.
  6.  
  7. On the doors with power operated components, install all previously removed parts.
  8.  

ADJUSTMENTS



  1. Adjust the door so that the door-to-body and lock-to-striker align properly.
  2.  
  3. The hinge-to-door bolts may need to be loosened to adjust the alignment properly.
  4.  

 
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