GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Kodiak C-Series (Conventional) C4/C5 🢒 Body 🢒 Doors 🢒 Front Side Door Upper Hinge and Lower Hinge Replacement

Removal Procedure
  1. Open the hood.
  2. Remove the black caps from the mirror bracket.

    3. Object Number: 820787 Size: SH
  3. Remove the 4 mirror nuts.

    4. Object Number: 803757 Size: SH
  4. Remove the mirror.
  5. Disconnect the electrical connector if applicable.
  6. Open the door.

    7. Object Number: 815532 Size: SH
  7. Remove the screws and the nuts from the A-pillar panel.
  8. Remove the A-pillar panel.

    9. Object Number: 803766 Size: SH
  9. Remove the mirror bracket nuts.
  10. Remove the mirror bracket.

    11. Object Number: 820776 Size: SH
  11. Remove the door check link bolts from body.

    12. Object Number: 820761 Size: SH
  12. Have an assistant hold the door.
  13. Remove the 4 bolts from the lower hinge door side.

    14. Object Number: 820778 Size: SH
  14. Remove the 4 bolts from the upper hinge door side.
  15. Remove the door with an assistant.

    16. Object Number: 803774 Size: SH
  16. Remove the 4 bolts from the lower hinge body side.
  17. Remove the lower hinge.

    18. Object Number: 803771 Size: SH
  18. Remove the 4 bolts from the upper hinge body side.
  19. Remove upper hinge.

Installation Procedure
  1. Install the upper hinge.

    2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 803771 Size: SH
  2. Install the 4 bolts to the upper hinge body side.

    3. Tighten
    Tighten the bolts to 34 N·m (25 lb ft).


    Object Number: 803774 Size: SH
  3. Install the lower hinge.
  4. Install the 4 bolts to the lower hinge body side.

    5. Tighten
    Tighten the bolts to 34 N·m (25 lb ft).

  5. Install the door with an assistant.

    6. Object Number: 820778 Size: SH
  6. Install the 4 bolts to the upper hinge door side.

    7. Tighten
    Tighten the bolts to 34 N·m (25 lb ft).

  7. Install the 4 bolts to the lower hinge door side.

    8. Object Number: 820776 Size: SH
  8. Install the door check link bolts to the body. Refer to Front Side Door Check Link Replacement .

    9. Object Number: 803766 Size: SH
  9. Install the mirror bracket.
  10. Install the mirror bracket nuts.

    11. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).


    Object Number: 820780 Size: SH
  11. Install the A pillar panel.

    12. Object Number: 815532 Size: SH
  12. Install the nuts and the screws to the A-pillar panel.

    13. Tighten
    Tighten the nuts and screws to 3 N·m (26 lb in).


    Object Number: 803757 Size: SH
  13. Install the mirror.
  14. Connect the electrical connector, if applicable.

    15. Object Number: 820787 Size: SH
  15. Install the 4 mirror nuts.

    16. Tighten
    Tighten the nuts and screws to 4 N·m (35 lb in).

  16. Install the black caps to mirror brackets.
  17. Close the hood.
  18. Close the door.