GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2000 🢒 Sunfire 🢒 Body and Accessories 🢒 Doors 🢒 Door Replacement

Removal Procedure
  1. Raise the window to the full UP position.
  2. Remove the door trim panel. Refer to Door Trim Panel Replacement .
  3. Remove the water deflector in order to access the wire harness. Refer to Door Water Deflector Replacement

    4. Object Number: 581510 Size: SH
  4. Disconnect the wire harness from all the components in the door.
  5. Remove the rubber conduit from the door.
  6. Remove the wire harness from the door through the conduit access hole.
  7. Support the door.
  8. Mark the position of the door hinge to the hinge pillar.
  9. Remove the lower hinge bolt (4) and nut (3) from the hinge pillar.
  10. Remove the upper hinge bolt (1) and nut (2) from the hinge pillar.
  11. Remove the door from the body.
  12. Mark the position of the door hinge to the door.
  13. Remove the lower hinge bolts from the door.
  14. Remove the upper hinge bolts from the door.

Installation Procedure

    Object Number: 581510 Size: SH

    Notice: Door hinge parts could cause damage to other door components if not replaced with the same part or equivalent. Do not use replacement parts of lesser quality or substitute design. Specified torque values must be used during assembly in order to ensure proper retention.

  1. Attach the upper hinge bolts snugly to the door in order to ensure that the door is movable.
  2. Attach the lower hinge bolts snugly to the door in order to ensure that the door is movable.
  3. Install the door to the body.
  4. Attach the upper hinge bolt (1) and nut (2) snugly in order to ensure that the door is movable.
  5. Attach the lower hinge bolt (4) and nut (3) snugly in order to ensure that the door is movable:
  6. Carefully close the door.
  7. Adjust the door for proper alignment.
  8. Slowly open the door.

    9. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  9. Install the upper hinge bolt (1) and nut (2) to the hinge pillar.

    10. Tighten
    Tighten the bolt (1) and nut (2) to 26 N·m (19 lb ft).

  10. Install the lower hinge bolt (4) and nut (3) to the hinge pillar.

    11. Tighten
    Tighten the bolt (4) and nut (3) to 26 N·m (19 lb ft).

  11. Install the upper hinge bolts to the door.

    12. Tighten
    Tighten the bolts to 26 N·m (19 lb ft).

  12. Install the lower hinge bolts to the door.

    13. Tighten
    Tighten the bolts to 26 N·m (19 lb ft).

  13. Inspect the door for proper alignment. Repeat the installation procedure from the beginning if the door is not aligned properly.
  14. Install the wire harness through the conduit access hole.
  15. Install the rubber conduit to the door.
  16. Connect the components to the door wire harness.
  17. Install the water deflector. Refer to Door Water Deflector Replacement .
  18. Install the trim panel. Refer to Door Trim Panel Replacement .