GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Door Panel

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REMOVAL & INSTALLATION



See Figures 1 through 10

A one piece trim panel is used on styles with standard trim. The custom trim has an upper metal trim panel. The one piece trim hangs over the door inner panel across the top and is secured by clips down the sides and across the bottom. It is retained by screws located in the areas of the top front of the panel assembly.

  1. Remove all door inside handles.
  2.  

Removing a window crank handle (with a retaining clip inside the handle) without a special tool can be a problem. An alternative method is to take a clean shop towel and wedge it between the window crank handle and the door panel. Move it up, while pulling it from left to right, as in a sawing motion working the clean shop towel until the retaining clip comes free.

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Fig. Fig. 1: The window crank handle may be removed with a clean shop towel

  1. Remove the door inside locking rod knob.
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  3. Unfasten the screws inserted through the door armrest and pull the handle assembly into the door inner panel or armrest hanger support bracket.
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Fig. Fig. 2: Use a suitable tool to remove the trim "buttons", then ...



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Fig. Fig. 3: ... remove the armrest retaining screws



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Fig. Fig. 4: Unfasten the retaining screw, then ...



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Fig. Fig. 5: ... remove the inside door handle trim piece

  1. On styles with remote control mirrors assemblies, disengage the end of the mirror control cable from the bezel on the standard trim, or from the upper trim panel on the custom trim. On custom trim, remove the upper trim panel.
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  3. On styles with power window or door lock controls located in the door trim panel, disconnect the wire harnesses at the switch assemblies. On the four door sedan and the two door hatchback, remove the switch cover by pushing down at the switch area and pulling down at the bottom of the cover. The switch and base may be removed from the trim with the cover removed.
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Fig. Fig. 6: Use of this special tool is the preferred method to remove the window crank handle



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Fig. Fig. 7: Remove the window crank handle, then ...



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Fig. Fig. 8: ... remove the washer from the door panel



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Fig. Fig. 9: A trim panel remover tool is very helpful to disengage the retainers when removing the door panel



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Fig. Fig. 10: Common front door trim panel retention and fastener locations

  1. Remove the remote control handle bezel screws.
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  3. Unfasten the screws used to hold the armrest to the inner panel.
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  5. Remove the screws and plastic retainers from the perimeter of the door trim using tool BT-7323A or equivalent and a screwdriver. To remove the trim panel, push the trim panel upward and outboard to disengage from the door inner panel at the beltline.
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  7. On styles with an insulator pad fastened to the door inner panel, use tool J-21104 or equivalent to remove the fasteners and the insulator pad.
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  9. On styles with the water defector held in place by fasteners, use tool BT-7323A or equivalent to remove the fasteners and the water deflector.
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  11. On styles with the armrest bracket riveted to the inner panel and installed over the water deflector, drill out the armrest bracket rivets using a 3 / 16 in. (5mm) drill bit.
  12.  

To install:
  1. To install the insulator pad or water deflector, locate the fasteners in the holes in the door inner panel and press in place. Replace all tape which may have been applied to assist in holding insulator pad or water deflector in place. Where necessary, install the armrest support bracket over the water deflector and onto the door inner panel using 3 / 16 in. x 11 / 32 in. (5mm x 9mm) rivets.
  2.  
  3. Before installing the door trim panel, check that all trim retainers are securely installed to the assembly and are not damaged. Replace retainers where required.
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  5. Attach all electrical components.
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  7. To install the door trim panel, locate the top of the assembly over the upper flange of the door inner panel, inserting the door handle through the handle slot in the panel and press down on the trim panel to engage the upper retaining clips.
  8.  
  9. Position the trim panel to the door inner panel so the trim retainers are align with the attaching holes in the panel and tap the retainers into the holes with the palm of your hand or a clean rubber mallet.
  10.  
  11. Install all previously removed items.
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