GM Full Size Vans 1987-1997 Repair Guide

Rear Door

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REMOVAL & INSTALLATION



1987-95 Models

See Figure 1

  1. Open the door, remove the door trim panel and disconnect the electrical wiring harness (if equipped). Then mark the position of the door on the hinges using a wax pencil.
  2.  
  3. Remove the hinge hole plugs on the body side pillar.
  4.  
  5. Remove the strap pin from the bracket, then remove the snapring from the pin, and pull the pin.
  6.  
  7. Support the door safely, and remove the hinge to body pillar bolts.
  8.  
  9. Remove the door from the vehicle.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Rear door mounting - 1987-95 models

To install:
  1. Install the door on the vehicle.
  2.  
  3. Align the hinges to the marks made during removal, then install the bolts.
  4.  
  5. Install the door pin, snap-ring and strap pin.
  6.  
  7. Engage the electrical connections and install the trim panel.
  8.  

1996-97 Models
LEFT SIDE

See Figure 2

  1. Remove the trim panel.
  2.  
  3. Remove the door extension as follows:
    1. Unfasten the extension retaining bolts.
    2.  
    3. Close the door partially and pull the extension rearward from the door.
    4.  

  4.  
  5. Remove the door latches and latch handle.
  6.  
  7. Tag and disengage the electrical connections from the door.
  8.  
  9. Remove the door glass.
  10.  
  11. Remove the weatherstrips.
  12.  
  13. Disconnect the speaker (if equipped).
  14.  
  15. Mark the position of the door on the hinges using a wax pencil.
  16.  
  17. Loosen the hinge-to-body retaining bolts.
  18.  
  19. Remove the door from the vehicle.
  20.  



Click image to see an enlarged view

Fig. Fig. 2: Rear door mounting - 1996-97 models

To install:
  1. Position the door. Align the hinges with marks made during removal, then tighten the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. If equipped, connect the speaker.
  4.  
  5. Install the weatherstrips.
  6.  
  7. Instaal the door glass, then engage the electrical connections.
  8.  
  9. Install the latch handle and latches.
  10.  
  11. Install the door extension as follows:
    1. Press the extension to engage it to the door, install the bolts and tighten them to 89 inch lbs. (10 Nm).
    2.  

  12.  
  13. Install the trim panel.
  14.  

RIGHT SIDE

See Figure 2

  1. Remove the trim panel.
  2.  
  3. Remove the door extension as follows:
    1. Unfasten the extension retaining bolts.
    2.  
    3. Close the door partially and pull the extension rearward from the door.
    4.  

  4.  
  5. Remove the inside and outside door handle.
  6.  
  7. Tag and disengage the electrical connections from the door.
  8.  
  9. Remove the door glass.
  10.  
  11. Remove the weatherstrips.
  12.  
  13. Disconnect the speaker (if equipped).
  14.  
  15. Mark the position of the door on the hinges using a wax pencil.
  16.  
  17. Loosen the hinge-to-body retaining bolts.
  18.  
  19. Remove the door from the vehicle.
  20.  

To install:

Install the door.

  1. Align the hinges with marks made during removal, then tighten the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. If equipped, connect the speaker.
  4.  
  5. Install the weatherstrips.
  6.  
  7. Install the door glass, then engage the electrical connections.
  8.  
  9. Install the inside and outside handles.
  10.  
  11. Install the door extension as follows:
  12.  



Press the extension to engage it to the door, install the bolts and tighten them to 89 inch lbs. (10 Nm).
 

  1. Install the trim panel.
  2.  

ADJUSTMENT



1987-95 Models

See Figure 3

There is no adjustment for the 1996-97 models.

Each of the two doors must first be adjusted in the door opening before adjusting the door-to-door clearance.

  1. Adjust the door height so that there is a gap of 0.23-0.27 in. (5.84mm-6.86mm) between the roof panel and the rear door panel.
  2.  

Adjust the gap between the bottom of the door panel (not the bottom of the outer panel) and the platform panel should be 0.23-0.27 in. (5.84mm-6.86mm). This measurement should be taken on each door individually from the side of the door. The door should be in its normal closed position. The outer rear door panel is 0.58-62 in. (14.75-15.75mm) away from the rear platform panel when normally closed.

Adjust the rear door outer panel to the body side outer panel gap to 0.14-18 in. (3.59-4.61mm).

  1. The door to door clearance between the left and right outer door panels should be 0.23-0.27 in. (5.84mm-6.86mm).
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Adjustment and gap specifications - 1987-95 models

 
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