Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Doors

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REMOVAL & INSTALLATION



See Figures 1 and 2

Two people are needed to replace the entire door assembly. Most components, including the hinges, can be replaced without removing the door from the vehicle and, thereby, eliminating the need for an assistant.

  1. For doors equipped with electrical components such as power windows or stereo speakers, disconnect the negative battery cable.
  2.  
  3. If applicable, disconnect the electrical wiring boot and unplug the wiring. Should the wiring connectors be unaccessible from the boot, the interior trim panel(s) must be removed so the wires can be disconnected. Refer to the procedure later in this section.
  4.  
  5. Remove the check link bolt(s) from the door or the body, whichever is accessible.
  6.  
  7. If the door is to be reinstalled, use a soft marker to outline the hinge positioning in relation to the door assembly.
  8.  
  9. While an assistant supports the door assembly, remove the bolts attaching the hinges to the door, then remove the door from the vehicle.
  10.  

To install:
  1. Have an assistant support the door assembly to the vehicle and secure using the bolts, but do not completely tighten at this time.
  2.  
  3. Adjust the door. Refer to the procedure later in this section. If reinstalling a door, use the marks made during removal as a starting point and adjust from there, as necessary. Then, tighten the hinge-to-door bolts to 26 ft. lbs. (35 Nm) on 1991-95 models or 22 ft. lbs. (30 Nm) on 1996-98 models.
  4.  
  5. Secure the check link to the door or body using the retaining bolt(s) and tighten to 12 ft. lbs. (16 Nm).
  6.  
  7. Connect the door wiring, then install the trim panel(s) and wiring boot, as applicable.
  8.  
  9. If removed, connect the negative battery cable.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: The door check link can be removed from the door only, or from the hinge pillar as well



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Fig. Fig. 2: Exploded view of the rear door hinge assembly

ADJUSTMENT



See Figures 3, 4 and 5

  1. Determine if adjustment is necessary by opening and closing the door checking for proper fit and alignment. Make sure the door does not bind on adjacent panels.
  2.  
  3. If adjustment is necessary, the door striker must be removed from the body. Use a soft marker to scribe alignment marks, then remove the screws, striker and, if present, shim(s) to allow for proper door adjustment.
  4.  
  5. To adjust the door up or down, loosen the 4 hinge-to-door bolts and position the door as needed.
  6.  
  7. To adjust the door in or out, loosen the 4 hinge-to-door bolts, one hinge at a time, and position the door as needed.
  8.  
  9. To adjust the door fore or aft, loosen the 4 hinge-to-body bolts, one hinge at a time, and position as needed.
  10.  
  11. When the door has been properly adjusted, tighten the hinge bolts to 26 ft. lbs. (35 Nm).
  12.  
  13. Loosely install the striker, screws and, if present, the shims. Align the striker with the marks made during removal and tighten the retainers to 18 ft. lbs. (25 Nm). Check striker alignment by closing the door.
  14.  
  15. If necessary, adjust the striker alignment. The striker may be adjusted up and down or in and out by loosening the screws and repositioning the striker. Fore and aft adjustments are made by adding or removing shims from the behind the striker. When adjustments are made, tighten the screws to 18 ft. lbs. (25 Nm).
  16.  



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Fig. Fig. 3: The striker must be removed when adjusting the door assembly



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Fig. Fig. 4: Loosen the body bolts only to make front and rearward door adjustments; loosen the door bolts to make all other adjustments



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Fig. Fig. 5: The striker panel can be adjusted up, down, in or out by loosening the retaining bolts

 
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