BODY AND TRIM

EXTERIOR

Doors

REMOVAL & INSTALLATION

Front

WARNING
The doors are heavier than they appear. Support the door from the bottom and use a helper during removal and installation. Do not allow the door to sag while partially attached and do not subject the door to impact or twisting motions.

1. Turn the ignition key to the OFF position. Disconnect the negative battery cable. Wait at least 90 seconds from the time the negative battery was disconnected to start work.

   CAUTION
   Some models covered by this manual may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Section 6.

2. If equipped with power door locks, windows or any other power option located on the door, remove the inner door panel and disconnect the electrical component.
3. Remove the wire harness retainers and extract the harness from the door.
4. Use a floor jack padded with rags or soft lumber to support the door at its lower midpoint. Use a felt tip marker to outline the hinge position on the door.
5. Disconnect the door check rod. To prevent the rod from falling inside the door, install the retainer into the hole in the end of the check rod.
6. Have a helper support the door, keeping it upright at all times. Remove the bolts holding the upper and lower hinges for the door.
7. Using two people, lift the door clear of the van.
8. The door hinge may be removed from the body if necessary.

   To install:

9. If the door hinge is removed from the body, reinstall it and tighten the bolts securely.
10. Place the door in position and support it. Use the jack to fine tune the position until the bolt holes and matchmark (hinge outline) align.
11. Apply an appropriate amount of multipurpose grease to the lower hinge and cam sliding area. Using engine oil, lubricate between the lower hinge pin and the roller.
12. Install the hinge bolts and nuts. Tighten the bolts securely.
13. If all has gone well, the door should almost be in the original position. Refer to the door adjustment procedures to align the door and body. It may be necessary to loosen the hinge bolts and reposition the door; remember to retighten them each time or the door will shift out of place.
14. Once adjusted, connect the door check lever and install the pin. Install the hinge covers if any were removed.
15. Route the wiring harness(es) into the body and connect them to their leads.
16. Connect the negative battery cable.
17. Test the operation of any electrical components in the door (locks, mirrors, speakers, etc.) and test drive the car, checking the door for air leaks and rattles.

Sliding

1. Using a taped flatbladed tool, remove the end molding from the door.
2. Remove the bolt and catch spring.
3. Remove the door handle with clip. Use a rag or special clip removal tool.

   Fig. 4: Using a rag to remove the sliding door handle clip

4. Slide the door rearward to disconnect the upper, lower and center rollers from the rails, then remove the sliding door.

   To install:

5. Slide the door forward to connect the center roller, the lower and upper rollers to the rails. install the sliding door.

   Fig. 5: Sliding the door into position during installation

6. Install and secure the bolt and catch spring.

   Fig. 6: Insert the bolt to secure the catch spring

7. Inspect the clips on the door molding. Replace any broken clips and attach to the door.