GM Full Size Vans 1987-1997 Repair Guide

Swing-Out Side Doors

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REMOVAL & INSTALLATION



1987-95 Models

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Side door wiring harness components - 1987-97 models

  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.  

To install:
  1. Install the door and door hinge-to-pillar bolts (finger-tight only).
  2.  
  3. Align the hinges with the marks made during removal. Tighten the bolts to 30 ft. lbs. (43 Nm).
  4.  
  5. Install the strap pin in the bracket and then the snap-ring to the pin.
  6.  
  7. Install the hinge hole caps.
  8.  
  9. Engage the electrical connections (if equipped).
  10.  
  11. Install door trim panel.
  12.  

1996-97 Models
SIDE FRONT DOOR

See Figure 2

Tool J-41226-50 hinge pin kit or its equivalent is required for this procedure.

  1. Remove the door trim panel and the swing out window.
  2.  
  3. Remove the inside and outside handles.
  4.  
  5. If necessary, remove the weatherstrip.
  6.  
  7. Remove the upper and lower wedges.
  8.  
  9. Remove the lock rod retainers by rotating it 90 degrees and pulling it out.
  10.  
  11. Remove the door latch, then tag and disengage the electrical connections.
  12.  
  13. Remove the door check strap by unfastening the bolts retaining.
  14.  
  15. Remove the check strap seal using a 3M® release agent or its equivalent, then clean all the old adhesive residue.
  16.  
  17. Remove the hinge pins using tool J-41226-50, or its equivalent.
  18.  
  19. Remove the door from the vehicle.
  20.  



Click image to see an enlarged view

Fig. Fig. 2: The hinge pins must be removed when removing the side doors - 1996-97 models

To install:
  1. Install the door on the vehicle.
  2.  
  3. Install the hinge pins using tool J-41226-50 or its equivalent.
  4.  
  5. Install the check strap seal and the check strap. Hook the strap in the door and pull to engage it, then tighten the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Engage all electrical connections and install the door latch.
  8.  
  9. Install the lock rod retainers by inserting them into the door and rotating them 90 degrees.
  10.  
  11. Install the upper and lower wedges.
  12.  
  13. Install the weatherstrips.
  14.  
  15. Install the inside and outside door handles.
  16.  
  17. Install the door glass and the trim panel.
  18.  

SIDE REAR DOOR

Tool J-41226-50 hinge pin kit or its equivalent is required for this procedure.

  1. Remove the door trim panel and the swing out window.
  2.  
  3. Remove the door glass.
  4.  
  5. If necessary, remove the weatherstrip.
  6.  
  7. Remove the upper and lower wedges.
  8.  
  9. Remove the upper and lower door latches.
  10.  
  11. Remove the latch rods from the door, then remove the latch handle.
  12.  
  13. Remove the latch striker.
  14.  
  15. Remove the hinge pins using tool J-41226-50, or its equivalent.
  16.  
  17. Remove the door from the vehicle.
  18.  

To install:
  1. Install the door on the vehicle.
  2.  
  3. Install the hinge pins using tool J-41226-50 or its equivalent.
  4.  
  5. Install the latch handle and striker.
  6.  
  7. Install the latch rods and the door latches.
  8.  
  9. Install the upper and lower wedges.
  10.  
  11. If removed, install the weatherstrips.
  12.  
  13. Install the door window glass.
  14.  
  15. Install the trim panel.
  16.  

ADJUSTMENT



See Figure 3

1987-95 Models

Door striker wrench J-29843-9, or its equivalent, is required to make this adjustment.

  1. Remove the door lock striker from the rear intermediate door using J-29843-9, or its equivalent.
  2.  
  3. Remove the upper and lower rear intermediate door strikers.
  4.  
  5. Loosen the hinge bolts as necessary to adjust the doors.
  6.  
  7. Each of the two doors must first be adjusted in the door opening before adjusting the door to door clearance.
  8.  
  9. Adjust the door up and down, forward and rearward, and in and out, at the door hinges.
  10.  
  11. Adjust the door height so that there is a gap of 0.16-20 in. (4-4.5mm) between the door and the roof panel.
  12.  

Adjust the gap between the door and the rocker panel to 0.23-24 in. (5.59mm-6.61mm).

  1. Adjust the gap between the doors and the body at the hinge pillars to 0.16-15.98 in. (3.59-4.61mm).
  2.  
  3. Adjust the gap between the front and rear intermediate doors to 0.23-24 in. (5.59mm-6.61mm).
  4.  
  5. Tighten the hinge bolts that were loosened.
  6.  
  7. Install the upper and lower rear intermediate door strikers to the body.
  8.  
  9. Install the door lock striker to the rear intermediate door using J-29843-9, or its equivalent.
  10.  
  11. Adjust the upper and lower intermediate door striker to door clearance so that there is 0.172 in. (4.37mm) between the striker and the door latch when the door is in the secondary latch position. (The door is latched but not fully closed.) An 11 / 64 in. diameter drill bit may be used to gauge this clearance.
  12.  
  13. Adjust the front intermediate striker on the rear door so that the front door lock properly engages the rear door, and so that the front door is flush with the rear door.
  14.  



Click image to see an enlarged view

Fig. Fig. 3: Adjustment points and gap specifications on swing-out side door - 1987-95 models

 
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