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2002 Avalanche 3-19
Front Door-Side
Hinge Replacement
Installation Procedure
1. Repair any damage done to door
during the drilling or the removal.
2. Clean and prepare the backing plate
mounting surfaces in order to
ensure a flush fit of the backing
plate.
3. Position the service hinge within the
scribe marks on the door.
4. Center punch each hole location on
the door according to the service
hinge.
5. Drill a 3 mm (1/8␣ in.) pilot hole at
each center punch location.
6. Drill a 13 mm (1/2␣ in.) hole at the
pilot locations.
IMPORTANT: Prior to refinishing,
refer to the publication GM4901M-
D-2000 “GM Approved Refinish
Materials” for recommended
products. Do not combine paint
systems. Refer to paint
manufacturer’s recommendations.
7. Clean and prepare all of the bare
metal surfaces.
8. Apply an approved anti-corrosion
primer.
9. Apply full-bodied caulk to the entire
hinge mounting surface in order to
ensure a proper seal.
10. Align the hinge and the backing
plate with the holes in the door
(Fig. 4-34).
11. Install the bolts. Tighten the bolts
to 25 ␣ N·m (18 ft lb).
12. Apply the sealers.
13. Refinish the metal surfaces as
necessary.
14. Install and align all of the related
panels and the components.
3 MM (1/8 IN)
PILOT
13 MM (1/2 IN)
DRILL
HINGE
DOOR
BOLTS
BACKING
PLATE