GM Cavalier/Sunfire 1995-2000 Repair Guide

Doors

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REMOVAL & INSTALLATION



  1. If equipped with power door components, disconnect the negative battery cable.
  2.  
  3. Make sure the window is raised up to its fully closed position.
  4.  
  5. Remove the door trim panel, as outlined later in this section.
  6.  
  7. If equipped with power door components, move the water deflector enough to access the door wiring harness, then detach the electrical connectors and remove the harness.
  8.  
  9. Remove the rubber conduit from the door.
  10.  
  11. Unfasten the door hold-open bolt.
  12.  
  13. Have an assistant support the door.
  14.  
  15. Matchmark the position of the door hinge to the hinge pillar. Unfasten the lower and upper hinge bolts from the pillar.
  16.  
  17. With an assistant's help, detach the door from the body.
  18.  
  19. Matchmark the position of the door hinge to the door, then unfasten the upper and lower hinge retaining bolts. Carefully remove the door from the vehicle.
  20.  

To install:
  1. Snug the upper and lower hinge-to-door bolts so the door can be moved.
  2.  
  3. With the aid of an assistant, position the door to the body.
  4.  
  5. Snug the upper and lower hinge-to-pillar bolts and nuts so that the door can be moved.
  6.  
  7. Carefully close the door. Adjust the door for proper alignment.
  8.  
  9. Slowly open the door.
  10.  
  11. Tighten the upper and lower hinge-to-pillar bolts and nuts to 16 ft. lbs. (22 Nm).
  12.  
  13. Tighten the upper and lower hinge-to-door bolts to 16 ft. lbs. (22 Nm).
  14.  
  15. Check the door for proper alignment. If the door does not align properly, readjust.
  16.  
  17. Install the door detent-to-hinge pillar bolt, then tighten to 80 inch lbs. (9 Nm).
  18.  
  19. If so equipped, install the electrical harness through the conduit access hole and connect the electrical connectors to the power door components.
  20.  
  21. Fasten the rubber conduit to the door.
  22.  
  23. Reposition and secure the door water deflector.
  24.  
  25. Install the inner door trim panel, as outlined later in this section.
  26.  
  27. Connect the negative battery cable.
  28.  

ADJUSTMENT



Door Height Adjustment

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Body clearance specifications

  1. Open the door and carefully loosen the hinge bolts.
  2.  
  3. Carefully slide the door up or down accordingly until the height is correct.
  4.  
  5. Tighten the hinge bolts to 16 ft. lbs. (22 Nm).
  6.  

Door Lock Striker Adjustment

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Door lock striker assembly and adjustment

  1. Loosen the two striker bolts.
  2.  
  3. Snug the striker bolts down but still enough to allow the striker to be moved.
  4.  
  5. Open and close the door and adjust the striker so that the door-to-body and lock-to-striker align properly.
  6.  
  7. tighten the striker bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. The hinge-to-door bolts may need to be loosened to adjust the alignment properly.
  10.  

 
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