For 1990-2009 cars

## Front Side Door Replacement Bolt On

### Removal Procedure

Important: Part interchangeability is not allowed between the weld-on door and the bolt-on door vehicles. Weld-on door vehicles must be serviced with parts designed for weld-on door applications. Bolt-on door vehicles must be serviced with parts designed for bolt-on door applications.

1. Remove the front door outer panel. Refer to Front Door Outer Panel removal procedure .
2. Remove the front door insulator. Refer to Front Door Insulator removal procedure .
3. Disconnect the wiring harness connectors.
4. Disengage the wiring harness grommet from the door structure and remove the wiring harness from the door.
5. Remove the check link to door structure bolt.
6. Support the door.
7. Remove the nuts and reinforcement plates from the door.
8. Remove the door from the vehicle.

### Installation Procedure

1. Install the door to hinge studs.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the reinforcement plates and nuts to the studs.

Tighten
Tighten the door and reinforcement plate-to-hinge nuts to 30 N·m (22 lb ft).

3. Install the check link-to-body structure bolt.

Tighten
Tighten the door check link-to-body bolt to 10 N·m (89 lb in).

4. Install the wiring harness grommet to the door.
5. Connect the wiring harness connectors.
6. Verify the door is aligned properly at the header, the front A-pillar, and the rear appliques. If the door adjustment is required, refer to Door Adjustment Front Door (Bolt On) procedure .
7. Install the front door insulator. Refer to Front Door Insulator installation procedure .
8. Install the front door outer panel. Refer to Front Door Outer Panel installation procedure .
9. Verify the door is aligned properly. Refer to Door Adjustment procedure .

## Front Side Door Replacement Weld On

#### Tools Required

J 42801 Hinge Pin Remover

### Removal Procedure

1. Remove the front door outer panel. Refer to Front Door Outer Panel Removal.
2. Remove the door sound deadener panel. Refer to Door Sound Deadener Panel Removal.
3. Disconnect the wiring harness connectors.
4. Disengage the wiring harness grommet from the door structure and remove the wiring harness from the door.
5. Remove the check link to door structure bolt.
6. Open the door and support it.
7. Remove the hinge pin caps.
8. Remove the hinge pins using J 42801 .
9. Remove the door.

### Installation Procedure

Important: Grease hinge pins before installation.

1. Place the door in the opening and support.
2. Install the door pins to hinges by tapping them into place.
3. Install the hinge caps.
4. Install the check link-to-door frame bolt.

Tighten
Tighten the door check link-to-door frame bolt to 10 N·m (89 lb in).

5. Connect the wiring harness connectors.
6. Install the wiring harness grommet to door structure.
7. Install the door sound deadener panel. Refer to Door Sound Deadener Panel Installation.
8. Install the front door outer panel. Refer to Front Door Outer Panel Installation.
9. Adjust the door. Refer to Door Adjustment.