Door - Service & Diagrams - (02)

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Trim Panel Replacement - 02 Hinge Pillar

Removal Procedure

(Refer to the drawing below)
 
   1. Remove door sill plate. Refer to Door Sill Plate Replacement - Front or Door Sill Plate Replacement - Rear .
   2. Remove hinge pillar panel.

Installation Procedure

(Refer to the drawing below)
 
   1. Install the hinge pillar panel.
   2. Install the door sill plate. Refer to Door Sill Plate Replacement - Front or Door Sill Plate Replacement - Rear .

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Door Sill Plate Replacement - Front

Removal Procedure

   1. Remove the sill plate. Firmly pull the sill plate up and out from the retainers.

(Refer to the drawing below)
 
   2. Remove the sill plate from the vehicle. Start from the front of the door sill. Use a flat-bladed tool in order to pry the door sill plate.

Installation Procedure

(Refer to the drawing below)

   1. Install the sill plate.
   2. Push the sill plate down until the sill plate locks into place.

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Door Sill Plate Replacement - Rear

Removal Procedure

(Refer to the drawing below)
 
   1. Use a flat-bladed tool in order to pry the door sill plate.
   2. Remove the sill plate from the vehicle.

Installation Procedure

(Refer to the drawing below)
 
   1. Install the sill plate.
   2. Push the sill plate down until the sill plate locks into place.

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Handle Bezel Replacement - Inside

Referenced by front door service documents, appears to be rear door.

Removal Procedure

   1. Insert a flat-bladed tool between the door handle bezel and the trim panel in order to release the handle bezel tab retainers.

(Refer to the drawing below)
 
   2. Remove the door handle bezel from the door panel.

Installation Procedure

(Refer to the drawing below)
 
   1. Position the door handle bezel in the door trim panel.
   2. Install the door handle bezel to the door panel by pressing the bezel into place until the bezel is completely seated.

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Door Replacement - 2002 Front

Removal Procedure

   1. Remove the door trim panel. Refer to Trim Panel Replacement - 2002 Front Door .
   2. Remove mirror. Refer to Mirror Replacement Power or Manual.
   3. Remove the window . Refer to Window Replacement - 2002 Front Door .
   4. Remove the window module. Refer to Module Replacement - Front Power Window .
   5. Remove the inside door handle. Refer to 2002 Door Handle Replacement - Inside .
   6. Remove the outside door handle. Refer to Door Handle Replacement - 2002 Outside .
   7. Remove the door lock actuator. Refer to Lock Actuator Replacement - 2002 Front Door .
   8. Remove the weatherstrip from the door. Refer to Weatherstrip Replacement - Front Door Upper and Opening.
   9. Disconnect the door wire harness. Refer to Wiring Harness Replacement - 02 Ft. Door .


 
  10. Remove the door check link bolt from the pillar side.
  11. Remove the bolts from the upper door hinge and the lower door hinge.
  12. With an assistant, lift the door up from the hinge pins, and remove the door from the vehicle.

Installation Procedure


 
   1. With an assistant, install the door to the vehicle by placing the door on the hinge pins.

      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.

   2. Install the bolts to the upper door hinge and the lower door hinge.

      Tighten

      Tighten the hinge bolts to 25 N·m (18 lb ft).

   3. Install the door check link bolt to the pillar side.

      Tighten

      Tighten the door check link bolt to 25 N·m (18 lb ft).

   4. Connect the door wire harness. Refer to Wiring Harness Replacement - Door .
   5. Install the weatherstrip to the door. Refer to Weatherstrip Replacement - Front Door .
   6. Install the door lock actuator. Refer to Lock Actuator Replacement - Front Door .
   7. Install the outside door handle. Refer to Door Handle Replacement - Outside .
   8. Install the inside door handle. Refer to Door Handle Replacement - Inside .
   9. Install the window module. Refer to Module Replacement - Front Power Window .
  10. Install the window . Refer to Window Replacement - Front Door .
  11. Install the mirror. Refer to Mirror Replacement .
  12. Install the door trim panel. Refer to Trim Panel Replacement - Side Front Door .
  13. Inspect the alignment of the door. Refer to Door Adjustment .

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Trim Panel Replacement - 2002 Front Door

Removal Procedure

   1. Remove the door handle bezel. Refer to Handle Bezel Replacement - Inside .
   2. Remove the window handle, if equipped. Refer to Window Handle Replacement .
   3. Remove the power accessory switch panel. Refer to Power Accessory Switch Panel Replacement .
   4. Remove the upper extension of the trim panel. Refer to Trim Panel Replacement - Upper Extension .
   5. Remove the manual lock lever from the trim panel using a flat bladed tool.
   6. Remove the trim panel screws.


 
   7. Remove the courtesy lamp, if equipped. Refer to Courtesy Lamp/Reflector Replacement - Door .
   8. Remove the trim panel from the door. Carefully slide the trim panel up in order to release the retainers from the door.
   9. Disconnect the electrical connectors.

Installation Procedure


 
   1. Connect the electrical connectors.
   2. Install the courtesy lamp, if equipped. Refer to Courtesy Lamp/Reflector Replacement - Door .
   3. Carefully align the panel, and slide the panel into the retainer slots in order to install the trim panel to the door.
   4. Install the window handle, if equipped. Refer to Window Handle Replacement .
   5. Install the power accessory switch panel. Refer to Power Accessory Switch Panel Replacement .

      Notice: Refer to Fastener Notice.

   6. Install the trim panel screws.

      Tighten

      Tighten the trim panel screws to 2 N·m (18 lb in).

   7. Install the manual lock lever to the trim panel.
   8. Install the upper extension of the trim panel. Refer to Trim Panel Replacement - Upper Extension .
   9. Install the door handle bezel. Refer to Handle Bezel Replacement - Inside .

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Mirror Replacement 2002 (Power Mirror)

Removal Procedure

   1. Remove the trim panel upper extension. Refer to Trim Panel Replacement - Upper Extension .


 
   2. Remove the insulator, if equipped.
   3. Disconnect the electrical connector.


 
   4. Remove the nuts securing the outside mirror to the door.
   5. Remove the mirror from the door.

Installation Procedure


 
   1. Install the outside mirror to the door. Press the mirror into place.


 
   2. Connect the electrical connector.

      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.

   3. Install the nuts in order to secure the outside mirror to the door.

      Tighten

      Tighten the outside mirror nuts to 9 N·m (80 lb in).

   4. Install the insulator, if equipped.
   5. Install the trim panel upper extension. Refer to Trim Panel Replacement - Upper Extension .

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2002 External Mirror Replacement (Manual)

Removal Procedure

   1. Remove the front door trim panel upper extension. Refer to Trim Panel Replacement - Upper Extension .


 
   2. Remove the nuts that retain the outside mirror to the door.
   3. Remove the outside mirror from the door.

Installation Procedure


 
   1. Install the rearview mirror to the door, pressing the outside mirror into place.

      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.

   2. Install the nuts in order to retain the outside mirror to the door.

      Tighten

      Tighten the outside rearview mirror retaining nuts to 9 N·m (80 lb in).

   3. Install the front door trim panel upper extension. Refer to Trim Panel Replacement - Upper Extension .

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Window Replacement - 2002 Front Door

Removal Procedure


 
   1. Partially raise the window.
   2. Remove the upper trim panel extension. Refer to Trim Panel Replacement - Upper Extension .
   3. Remove the manual door-lock lever.
   4. Remove the manual window handle, if equipped. Refer to Window Handle Replacement
   5. Remove the power accessory switch panel, if equipped. Refer to Power Accessory Switch Panel Replacement .
   6. Remove the door trim panel. Refer to Trim Panel Replacement - Side Front Door .
   7. Remove the water deflector. Refer to Water Deflector Replacement - Front Door .
   8. Remove the front bolt attachment from the window run channel.

      Important: Do not remove the bolts.

   9. Loosen the 2 retaining bolts (2) from the window assembly.
  10. Remove the window glass (3) from the door by sliding the window glass out through the top.

Installation Procedure


 
   1. Install the window glass (3) to the door.

      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.

   2. Tighten the 2 retaining bolts (2) to the window assembly.

      Tighten

      Tighten the bolts to 12 N·m (9 lb ft).

   3. Install the window run channel bolt .

      Tighten

      Tighten the bolts to 9 N·m (80 lb in).

   4. Install the water deflector. Refer to Water Deflector Replacement - Front Door .
   5. Install the door trim panel. Refer to Trim Panel Replacement - Side Front Door .
   6. Install the power accessory switch panel. Refer to Power Accessory Switch Panel Replacement .
   7. Install the manual window handle, if equipped. Refer to Window Handle Replacement .
   8. Install the manual door-lock lever.
   9. Install the upper trim panel extension. Refer to Trim Panel Replacement - Upper Extension .
  10. Inspect the operation of the window.

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Door Handle Replacement - Inside 2002

Removal Procedure

   1. Remove the trim panel. Refer to Trim Panel Replacement - Side Front Door .


 
   2. Remove the mounting bolts from the inside door handle.
   3. Slide the inside door handle forward in order to release the unit from the door.


 
   4. Disconnect the control rod from the inside door handle.
   5. Remove the door handle assembly from the door.

Installation Procedure


 
   1. Connect the control rod to the inside door handle.


 
   2. Slide the handle into place.

      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.

   3. Install the retaining bolts to the inside door handle.

      Tighten

      Tighten the door handle retaining bolts to 9 N·m (80 lb in).

   4. Install the trim panel. Refer to Trim Panel Replacement - Side Front Door .

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Door Handle Replacement - 2002 Outside

Removal Procedure

   1. Remove the trim panel. Refer to Trim Panel Replacement - Side Front Door or to Trim Panel Replacement - Side Rear Door .
   2. Remove the water deflector. Refer to Water Deflector Replacement - Front Door .


 
   3. Remove the outside handle rod from the rod clip.


 
   4. Remove the lock cylinder rod from the rod clip.
   5. Apply masking tape across the door handle on the outside of the door to secure the handle while removing the nuts.
   6. Remove the outside handle mounting nuts.


 
   7. Remove the rubber cover in order to access the outboard nut.
   8. Remove the door-lock cylinder from the outside handle housing.
      In order to repair a binding lock cylinder, refer to Binding Lock Cylinders .


 
   9. Remove the handle.

Installation Procedure


 
   1. Install the handle to the vehicle.
   2. If the lock cylinder is replaced, apply lubricant GM P/N 12345120, Canadian P/N 726548, or equivalent, to the inside of the lock case and of the cylinder keyway.
   3. Install the door-lock cylinder to the outside handle housing.
      In order to code a new lock cylinder, refer to Key and Lock Cylinder Coding in General Information.


 
   4. Install the lock cylinder clip to the lock cylinder rod.

 
   5. Install the handle rod to the handle assembly clip.

      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.

   6. Install the outside handle mounting nuts.

      Tighten

      Tighten the nuts to 9 N·m (80 lb in).


 
   7. Install the rubber cover.
   8. Install the water deflector. Refer to Water Deflector Replacement - Front Door .
   9. Install the trim panel. Refer to Trim Panel Replacement - Side Front Door or to Trim Panel Replacement - Side Rear Door .

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Lock Actuator Replacement - Front Door

Removal Procedure

   1. Raise the window glass.
   2. Remove the door trim panel. Refer to Trim Panel Replacement - Side Front Door .
   3. Remove the water deflector. Refer to Water Deflector Replacement - Front Door .


 
   4. Disconnect the inside door lock rod from the handle retainer clip.


 
   5. Disconnect the manual door lock rod from the door retainer clips.


 
   6. Remove the rubber plug (1) in order to disengage the outside handle rod retainer.


 
   7. Disconnect the cylinder lock rod (1).
   8. Remove the bolts (2) which retain the door lock actuator to the door.
   9. Remove the door lock actuator and the control rods as an assembly.
  10. Disconnect the electrical connector from the door lock actuator, if equipped.
  11. Remove the control rods as necessary.

Installation Procedure

   1. Install the control rods to the assembly.
   2. Connect the electrical connectors to the door lock actuator, if equipped
   3. Install the door lock actuator to the door.
   4. Connect the control rod to the outside door handle.
   5. Connect the cylinder lock rod.

      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.

   6. Install the bolts that retain the door lock actuator to the door.

      Tighten

      Tighten the screws to 9 N·m (80 lb in).


 
   7. Connect the manual door lock to the door retainer clips.


 
   8. Connect the control rod for the inside door handle to the lock assembly (1).


 
   9. Connect the inside door lock rod to the handle retainer clip.
  10. Install the water deflector. Refer to Water Deflector Replacement - Front Door .
  11. Install the door trim panel. Refer to Trim Panel Replacement - Side Front Door .
  12. Inspect the operation of all the related components.

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Weatherstrip Replacement - Front Door (Upper)

Removal Procedure

   1. Open the door.


 
   2. Pull the roof drip molding from the pinchweld and the windshield molding flange.

Installation Procedure

   1. Position the roof drip molding over the pinchweld.
   2. Install the roof drip molding by pressing on the pinchweld flange until fully seated.
   3. Close the door.

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Weatherstrip Replacement - Front Door (Door Opening)

Removal Procedure

   1. Open the door.
   2. Remove the sill plate. Refer to Door Sill Plate Replacement - Front in Interior Trim.
   3. Remove the hinge pillar trim panel. Refer to Trim Panel Replacement - Hinge Pillar in Interior Trim.
   4. Remove the windshield pillar molding. Refer to Garnish Molding Replacement - Windshield Pillar in Interior Trim.


 
   5. Remove the weatherstrip from the rear side door opening. Peel the unit away from channel, pulling the weatherstrip from the pinchweld flange.

Installation Procedure


 
   1. Install the weatherstrip from the rear side door opening fully seating the weatherstrip into the channel.
   2. Install the windshield pillar molding. Refer to Garnish Molding Replacement - Windshield Pillar in Interior Trim.
   3. Install the hinge pillar trim panel. Refer to Trim Panel Replacement - Hinge Pillar in Interior Trim.
   4. Install the sill plate. Refer to Door Sill Plate Replacement - Front in Interior Trim.
   5. Check door closing effort and seal to door fit.

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02 Front Door Window Regulator R&R By CAFCNA Member: Devlin

(1 of 2)

"I have to give credit to the guys over at A1 Electric Automotive Accessories for their tutorial which can be found here: http://www.a1electric.com/install/silver/s-02.htm

This really helped with the decision to go it alone on this repair, once I get my parts in I will take more pics of the final install.

For anyone interested I have a powerpoint with larger photos that I can share just send me a PM and I'll send it your way.



Tools required 1 - 7mm Socket with driver
1 Standard Screwdriver



Remove the manual locking mechanism with screwdriver prying gently from underneath the edges till it pops loose.



Remove the insert around the door handle again using the screw driver to pry gently.



The first screw to remove is visible just under the interior door handle. The second screw is under the set of control switches for the locks and windows
on the drivers door.



Here is the second screw you will need to remove underneath the control switches.



This view is of the triangle shaped piece of trim at the corner of the window closest to the mirror it pops loose quite easily no need for screw driver.



Do not forget to disconnect the speaker wire before removing the door panel.



The control switch just pops out with a little persuasion  I had no need for screw driver on my truck.



There are three small wiring harnesses to unplug for the control panel.



From what I can tell there are six bolts that have to come out to remove the window regulator assembly. Door handle will likely have to be removed
as well.



Here is where we connect the power to the new motor the wire is already to go just a quick connect plug."

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02 Front Door Window Regulator R&R By CAFCNA Member: Devlin

(2 of 2)

So let's start with the good news, I received my part in the mail today and installed it this evening. During the removal of the old window regulator assembly I notice something sparkling inside the door sill. See the pic below



Yup it's broken window glass, not a good sign. Seeing as how I bought the vehicle used from the Chevy Dealer in town here. Yes of course I asked during the sale if the truck had been in any accidents. No sir none at all was the response. I plan on following up with the dealer and the vehicles previous owner.  Not sure what I can do here, any advice would be welcome.




This image shows how the window regulator will sit once it is inside the door, the window regulator just slips into the opening below the door handle (NOTE: I did not have to remove my door handle during the install)

The window regulator is then screwed into place by the six bolts we removed in the previous post above.

Anyway onto the install.





The rubber piece that my thumb is touching needs to be reomved from the old window regulator assembly it just slips out quite easily, this rubber bracket is where the bottom of the window rests, a screw forces the clamps together and pinches the window in place.



WORD OF WARNING - Please ensure you tape your window in place when it is fully to the top of the window frame and do this before you loosen the two screws that pinch it in place.  I would advise anyone attempting this repair to also read this how-to http://www.a1electric.com/install/silver/s-02.htm

It was extremely helpful in explaining the process of installing a power window regulator assembly.

One last note as can be seen in the previous post the motor gets it's power through a quick connect clip in electrical connection. So no complicated wiring if you are doing a replacement like I had to.

Some pics of the old window regulator assembly I removed, note the rust.





Bits of glass and the wire from the old window regulator that had to be cut when the regulator failed.

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Document ID# 619853
2002 Chevrolet Avalanche

Courtesy Lamp/Reflector Replacement - Rear Door

Removal Procedure



   1. Gently push the assembly toward the front edge of the door.
   2. Lift the rear of the assembly from the door by using a small flat tool.
   3. Remove the courtesy lamp/reflector from the door panel.
   4. Twist and remove the socket container from the housing.
   5. Remove the bulb from the socket (if replacement is required).

Installation Procedure



   1. Install the bulb into the socket.
   2. Install the lens to the vehicle.
   3. Install the bulb and socket assembly into the housing into the lens (if equipped).
   4. Insert the tab on the assembly into the slot in the door panel at the front edge.
   5. Pivot the assembly into the door panel.
   6. Press the lens at the rear until the lens snaps into place.