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    GM S10/S15/Sonoma Pick-Ups 1982-1993 Repair Manual

    Door Hinges

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    The following procedure requires the use of an1/8in. (1mm) drill bit,1/2in. (11mm) drill bit, a center punch, a cold chisel, a portable body grinder, a putty knife and a scribing tool. Because this procedure requires opening a pinch weld, access to a welder is advisable to properly finish installation.

    REMOVAL & INSTALLATION



    See Figures 1 through 5

    1. Remove the door, and place it on a padded workbench.
    2.  
    3. If necessary, use a putty knife to remove the sealant from the around the edge of the hinge.
    4.  
    5. Outline the position of the hinge(s) on the door and the body pillar using a scribing tool.
    6.  
    7. Center punch the hinge-to-door and the hinge-to-body pillar welds.
    8.  
    9. Drill a pilot hole through each weld using a 1 / 8 in. (1mm) drill bit. Drill only enough to penetrate the hinge base plate.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 1: Marking the door hinges for replacement



    Click image to see an enlarged view

    Fig. Fig. 2: Use a drill to remove the door hinge welds

    When drilling the holes through the hinge welds, DO NOT drill through the door or the body pillar.

    1. Using a 1 / 2 in. (11mm) bit, drill a hole through the hinge base, following the 1 / 8 in. (1mm) pilot hole. Once again, only drill through the hinge base.
    2.  
    3. Use a cold chisel and a hammer to separate the hinge from the door and/or the body pillar.
    4.  
    5. If replacing the upper door hinge it may be necessary to remove the instrument panel attaching screws, then pull the panel outward and support.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 3: Exploded view of the service replacement bolt-on hinges

    1. Prepare the surface for the replacement hinge(s) using a file or a portable grinder. Clean off any welds remaining on the door or the body pillar.
    2.  

    To install:
    1. Align the bolt-on replacement hinge with the scribe lines made during removal.
    2.  
    3. Using the new hinge as a template, mark the location of each bolt hole using the center punch.
    4.  
    5. Drill holes (using the center marks as a guide) through the door and body pillar using a 1 / 2 in. (11mm) drill bit.
    6.  
    7. Using a hammer and cold chisel, open the door pillar (body side) pinch weld sufficiently to install the tapped anchor plate.
    8.  
    9. Coat the surface of the hinge that mates to the pillar and door using a medium bodied sealer.
    10.  
    11. Install the hinge bolts and tapped backing plate by aligning the components with the holes in the hinge pillar and door. Place the bolts through the hinge, pillar and/or door and into the tapped backing plate. It is advisable to attach a wire to the instrument panel side of the front lower pillar tapped backing plate in order to aid in aligning the holes. Once the bolts are all threaded, tighten them evenly to 24 ft. lbs. (13 Nm).
    12.  



    Click image to see an enlarged view

    Fig. Fig. 4: Using a cold chisel to open the door pillar pinch weld



    Click image to see an enlarged view

    Fig. Fig. 5: The door pillar must be opened sufficiently to install the tapped anchor plate

    1. Close the opening in the pinch weld and, if possible, spot weld to secure the flange.
    2.  
    3. Refinish and paint the door frame and/or pinch weld.
    4.  
    5. If the instrument panel was repositioned for access, pivot and secure the panel.
    6.  
    7. Install the door and properly adjust the new bolt-on hinges. For details, please refer to the hinge adjustment procedure found later in this section. Check the door-to-frame fit and that the striker properly engages the lock fork bolt.
    8.  

    ADJUSTMENT 1 / 2 in. (11mm) drill hinge holes with the service replacement bolt-on door hinges provide for some adjustment.



    The

    1. Loosen the striker and door hinge bolts, then adjust the door up, down, forward, rearward, in or out (as necessary) at the door hinges.
    2.  
    3. Hold the door in position (an assistant is helpful here) and tighten the hinge bolts slightly, then check the for the following specified gaps:

      Door-to-rocker panel-0.21-0.25 in. (3-5mm)
       
      Door-to-roof panel-0.21-0.25 in. (3-5mm)
       
      Rear of door-to-rear of pillar-0.14-0.22 in. (2-4mm)
       
      Forward edge of door-to-front fender-0.14-0.22 in. (2-4mm)
       
      Door surface flush with other panels to within-0.01 in. (1mm)
       

    4.  
    5. Make sure that the striker properly engages the lock fork bolt.
    6.  
    7. When all adjustments are complete, tighten the hinge bolts to 24 ft. lbs. (13 Nm), then tighten the striker bolts securely.
    8.  

     
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