Sunday, May 15, 2011

How to remove door panel, door window motor and regulator on 1991 cavalier?



REMOVAL & INSTALLATION



See Figures 1 through 10

A one piece trim panel is used on styles with standard trim. The custom trim has an upper metal trim panel. The one piece trim hangs over the door inner panel across the top and is secured by clips down the sides and across the bottom. It is retained by screws located in the areas of the top front of the panel assembly.

  1. Remove all door inside handles.

Removing a window crank handle (with a retaining clip inside the handle) without a special tool can be a problem. An alternative method is to take a clean shop towel and wedge it between the window crank handle and the door panel. Move it up, while pulling it from left to right, as in a sawing motion working the clean shop towel until the retaining clip comes free.

Click image to see an enlarged view

Fig. Fig. 1: The window crank handle may be removed with a clean shop towel

  1. Remove the door inside locking rod knob.
  2. Unfasten the screws inserted through the door armrest and pull the handle assembly into the door inner panel or armrest hanger support bracket.



Click image to see an enlarged view

Fig. Fig. 2: Use a suitable tool to remove the trim "buttons", then ...



Click image to see an enlarged view

Fig. Fig. 3: ... remove the armrest retaining screws



Click image to see an enlarged view

Fig. Fig. 4: Unfasten the retaining screw, then ...



Click image to see an enlarged view

Fig. Fig. 5: ... remove the inside door handle trim piece

  1. On styles with remote control mirrors assemblies, disengage the end of the mirror control cable from the bezel on the standard trim, or from the upper trim panel on the custom trim. On custom trim, remove the upper trim panel.
  2. On styles with power window or door lock controls located in the door trim panel, disconnect the wire harnesses at the switch assemblies. On the four door sedan and the two door hatchback, remove the switch cover by pushing down at the switch area and pulling down at the bottom of the cover. The switch and base may be removed from the trim with the cover removed.



Click image to see an enlarged view

Fig. Fig. 6: Use of this special tool is the preferred method to remove the window crank handle



Click image to see an enlarged view

Fig. Fig. 7: Remove the window crank handle, then ...



Click image to see an enlarged view

Fig. Fig. 8: ... remove the washer from the door panel



Click image to see an enlarged view

Fig. Fig. 9: A trim panel remover tool is very helpful to disengage the retainers when removing the door panel



Click image to see an enlarged view

Fig. Fig. 10: Common front door trim panel retention and fastener locations

  1. Remove the remote control handle bezel screws.
  2. Unfasten the screws used to hold the armrest to the inner panel.
  3. Remove the screws and plastic retainers from the perimeter of the door trim using tool BT-7323A or equivalent and a screwdriver. To remove the trim panel, push the trim panel upward and outboard to disengage from the door inner panel at the beltline.
  4. On styles with an insulator pad fastened to the door inner panel, use tool J-21104 or equivalent to remove the fasteners and the insulator pad.
  5. On styles with the water defector held in place by fasteners, use tool BT-7323A or equivalent to remove the fasteners and the water deflector.
  6. On styles with the armrest bracket riveted to the inner panel and installed over the water deflector, drill out the armrest bracket rivets using a 3 / 16 in. (5mm) drill bit.

To install:
  1. To install the insulator pad or water deflector, locate the fasteners in the holes in the door inner panel and press in place. Replace all tape which may have been applied to assist in holding insulator pad or water deflector in place. Where necessary, install the armrest support bracket over the water deflector and onto the door inner panel using 3 / 16 in. x11 / 32 in. (5mm x 9mm) rivets.
  2. Before installing the door trim panel, check that all trim retainers are securely installed to the assembly and are not damaged. Replace retainers where required.
  3. Attach all electrical components.
  4. To install the door trim panel, locate the top of the assembly over the upper flange of the door inner panel, inserting the door handle through the handle slot in the panel and press down on the trim panel to engage the upper retaining clips.
  5. Position the trim panel to the door inner panel so the trim retainers are align with the attaching holes in the panel and tap the retainers into the holes with the palm of your hand or a clean rubber mallet.
  6. Install all previously removed items.

-----------------------

REMOVAL & INSTALLATION



See Figures 1 and 2

  1. On doors equipped with power operated components proceed as follows:
    1. Remove the door trim panel, insulator pad (if so equipped), and the inner panel water deflector.
    2. Disconnect the wiring components inside the door.
    3. Remove the rubber conduit from the door, then remove the wiring harness from the door through the conduit access hole.

      Click image to see an enlarged view

      Fig. Fig. 1: You can use this tool to remove the spring



      Click image to see an enlarged view

      Fig. Fig. 2: View of the door hinge assembly - 1991 vehicle shown


  2. Tape the area (on the door pillar and body pillar) above the lower hinge with fabric tape.


CAUTION
Before performing the following step, cover the spring with a towel to prevent the spring from flying out and possibly causing personal injury!

  1. Insert a suitable, long, flat bladed tool under the pivot point of the hold-open link and over top of the spring. The tool should be positioned so as not to apply pressure to the hold-open link. Cover the spring with a shop cloth and lift the tool to disengage the spring. The spring can also be removed by using tool J-28625, or equivalent, door hinge spring compressor tool. The tool is stamped right side and left side. For all the J-cars the tool stamped, "left side" is used to service the right side hinge spring. The tool stamped, "right side" is used to service the left hand hinge spring.
    1. Install the two jaws of the tool over the spring. The jaw with the slots slides over spring at the hold-open link. The jaw with the hole fits over the spring at the bubble on the door hinge pillar.
    2. Install the bolt to the jaws of the tool and tighten to compress the spring.
    3. Remove the tool and spring from the door hinge assembly. Do not remove the spring from the tool.

  2. When removing the hinge pin, save the "barrel" clips as follows:
    1. Using two, suitable, flat bladed tools, spread the clip enough to move the clip above the recess toward the pointed end of the pin.
    2. As the pin is removed, the clip will ride the shank of the pin and fall free.
    3. Reinstall the clips onto the pins before installing the door.

  3. With the aid of a helper to support the door, remove the lower hinge pin, using a soft headed hammer and locking type pliers. The helper can aid in removing the hinge pin by raising and lowering the rear of the door.
  4. Insert the bolt into the hole of the lower hinge to maintain door attachment during upper hinge pin removal.
  5. Remove the upper hinge pin in the same manner as the lower. Remove the bolt from the lower hinge and remove the door from the body.

To install:

Before installing the door, replace the hinge pin clips or reuse the old clips as explained in the removal procedure.

  1. With the aid of a helper, position the door and insert a bolt in the lower hinge hole.
  2. The upper hinge pin is inserted with the pointed end up. The lower hinge pin is inserted with the pointed end down. With the door in the full open position, install the upper hinge pin using locking-type pliers and a soft headed hammer. Use a drift punch and hammer to complete pin installation.
  3. Remove the screw from the lower hinge and install the lower hinge pin. The use of the special tool J-28625 or equivalent is the recommended method for installing the hinge spring.


WARNING
If the spring is installed before installing the upper hinge pin, damage to the hinge bushings may result!

  1. If the spring was removed using a long, flat bladed tool, install the spring as follows:
    1. Place the spring in tool J-28625 or equivalent.
    2. Place the tool and spring in a bench vise.
    3. Compress the tool in a vise and install the bolt until the spring is fully compressed.
    4. Remove the tool with the compressed spring from the vise and install in the proper position in the door lower hinge. The slot in the jaw of the tool fits over the hold-open link. The hole in the other jaw fits over the bubble.
    5. Remove the bolt from the tool to install the spring.
    6. Remove the tool from the door hinge. (The tool will fall out in three pieces). Cycle the door to check spring operation.

  2. If tool J-28625 or equivalent was used to remove the spring, follow Steps d, e, and f above to install the spring.
  3. Remove the tape from the door and body pillars.
  4. On the doors with power operated components, install all previously removed parts.

ADJUSTMENTS



  1. Adjust the door so that the door-to-body and lock-to-striker align properly.
  2. The hinge-to-door bolts may need to be loosened to adjust the alignment properly.

-----------------

Front Window Regulator And Motor

The following procedure includes both manual and power window regulator removal and installation. Besides the regulators, window motors and rollers including the washer and pin are serviced separately.

REMOVAL & INSTALLATION



Except Convertible
  1. Remove the door trim panel and the water deflector.
  2. Raise the glass to the full up position and tape the glass to the door frame using fabric tape.
  3. Punch out the center pins of the regulator rivets using a 1 / 4 in. (6mm) drill bit. On electric regulators, drill out the rivets supporting the motor to the door inner panel.
  4. Move the regulator rearward and disconnect the wiring harness from the motor, if so equipped. Disengage the roller on the regulator lift arm from the glass sash channel.
  5. Remove the regulator through the rear access hole.
  6. Using a 3 / 16 in. (5mm) drill bit, drill out the motor attaching rivets and remove the motor from the regulator, if so equipped.

To install:
  1. If so equipped, attach the motor to the regulator using a rivet tool and 3/ 16 in. (5mm) rivets or 3 / 16 in. (5mm) nuts and bolts.
  2. Place the regulator through the rear access hole into the door inner panel. If an electric regulator is being installed, connect the wire connector to the motor prior to installing the regulator in the panel.
  3. Locate the lift arm roller into the glass sash channel.
  4. Using rivet tool J-29022 or equivalent, rivet the regulator to the inner panel of the door using 1 / 4 in. x 1 / 2 in. (6mm x 13mm) aluminum peel type rivets (part No. 9436175 or equivalent). If a rivet tool is not available, use the following nut and bolt method:
    1. Install U-clips on the regulator and motor (if so equipped), at the attaching locations. Be sure to install clips with clinch nuts on the outboard side of the regulator.
    2. Place the regulator through the rear access hole into the door inner panel. If an electric regulator is being installed, connect the wire connector to the motor prior to installing the regulator in the panel.
    3. Locate the lift arm roller into the glass sash channel.
    4. Align the regulator with the clinch nuts to the holes in the inner panel.
    5. Attach the regulator and motor to the door inner panel with 1 / 4in. screws. Tighten the screws to 90-125 inch lbs. (10-14 Nm).

  5. If an electrical window regulator is being installed use a rivet mentioned in step 10 to rivet the regulator motor to the door inner panel.
  6. Replace all previously removed parts.

Convertible
  1. Remove the door trim panel, sound absorber, armrest bracket and water deflector.
  2. Using a 1 / 4 in. (6mm) drill bit, drill out the rivets supporting the motor to the door inner panel.
  3. Disconnect the electrical connector from the regulator motor.
  4. Support the door glass in the full-up position, using rubber wedge door stops.
  5. Remove the nuts holding the cam assembly door reinforcement to the inner panel and remove the cam assembly.
  6. Remove the bolt holding the upper portion of the rear cam assembly to the inner panel.
  7. Using a 3 / 16 in. (5mm) drill bit, drill out the rivets, holding the lower section of the rear cam assembly to the inner panel.
  8. Remove the up stop from the rear cam assembly.
  9. Remove the rear cam assembly through the access hole.
  10. Disengage the regulator from the glass sash channel and remove the regulator through the access hole.


CAUTION
When removing the electric motor from the regulator, the sector gear must be locked in position. The regulator lift arm is under tension from the counterbalance spring and could cause personal injury if the sector gear is not locked in position.

  1. If equipped with an electric window regulator and you wish to remove the motor from the regulator proceed as follows:
    1. Drill a hole through the regulator sector gear and backplate and install a bolt and nut to lock the sector gear in position.
    2. Using a 3 / 16 in. (5mm) drill bit, drill out the motor attaching rivets and remove the motor from the regulator.
    3. To install the motor to the regulator use a rivet tool J-29022 or equivalent and install 3 / 16 in. (5mm) rivets or 3 / 16 in. (5mm) nuts and bolts. Remove the bolt and nut used to secure the sector gear in position.


To install:
  1. Make sure the regulator is in the full up position.
  2. Install the regulator arm rollers to the glass sash channel.
  3. Install the rear cam assembly using 3 / 16 in. (5mm) aluminum peel-type rivets making sure to install the up stop in the cam assembly.
  4. Connect the electrical connector to the motor on the regulator.
  5. Engage the roller on the regulator lift arm in the cam assembly door reinforcement.
  6. Install the cam assembly door reinforcement to the inner panel.
  7. Align the attaching holes in the regulator with the holes in the inner panel.
  8. Install the regulator to the inner panel, using a rivet gun and 1 / 4 in. x 1/ 2 in. (6mm x 13mm) aluminum peel type rivets.

--------------------

Rear Window Regulator

The following procedure includes both manual and power window regulator removal and installation. Besides the regulators, window motors and rollers including the washer and pin are serviced separately.

REMOVAL & INSTALLATION



  1. Remove the door trim panel and the water deflector.
  2. Raise the glass to the full up position and tape the glass to the door frame using fabric tape.
  3. Punch out the center pins of the regulator rivets using a 1 / 4 in. (6mm) drill bit. On electric regulators, drill out the rivets supporting the motor to the door inner panel.
  4. Disconnect the wiring harness from the motor, if so equipped. Disengage the roller on the regulator lift arm from the glass sash channel.
  5. Remove the regulator through the rear access hole.
  6. Using a 3 / 16 in. (5mm) drill bit, drill out the motor attaching rivets and remove the motor from the regulator, if so equipped.

To install:
  1. If so equipped, attach the motor to the regulator using a rivet tool and 3/ 16 in. (5mm) rivets or 3 / 16 in. (5mm) nuts and bolts.
  2. Place the regulator through the rear access hole into the door inner panel. If an electric regulator is being installed, connect the wire connector to the motor prior to installing the regulator in the panel.
  3. Locate the lift arm roller into the glass sash channel.
  4. Using rivet tool J-29022 or equivalent, rivet the regulator to the inner panel of the door using 1 / 4 in. x 1 / 2 in. (6mm x 13mm) aluminum peel type rivets (part No. 9436175 or equivalent). If a rivet tool is not available, use the following nut and bolt method:
    1. Install U-clips on the regulator and motor (if so equipped), at the attaching locations. Be sure to install clips with clinch nuts on the outboard side of the regulator.
    2. Place the regulator through the rear access hole into the door inner panel. If an electric regulator is being installed, connect the wire connector to the motor prior to installing the regulator in the panel.
    3. Locate the lift arm roller into the glass sash channel.
    4. Align the regulator with the clinch nuts to the holes in the inner panel.
    5. Attach the regulator and motor to the door inner panel with 1 / 4in. screws. Tighten the screws to 90-125 inch lbs. (10-14 Nm).

  5. If an electrical window regulator is being installed use a rivet mentioned in step 10 to rivet the regulator motor to the door inner panel.
  6. Replace all previously removed parts.

-----------------

REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Raise the window to the full up position.
  2. Remove the inside door trim panel.



Click image to see an enlarged view

Fig. Fig. 1: Front door lock bellcrank and actuator - 1992 vehicle shown



Click image to see an enlarged view

Fig. Fig. 2: Rear door lock system - 1992 vehicle shown

  1. Detach the water deflector enough to access the lock actuator.
  2. Disconnect the outside handle-to-lock assembly rod.
  3. Disconnect the lock cylinder-to-lock assembly rod.
  4. Disconnect the inside handle-to-lock assembly rod.
  5. Unfasten the lock assembly screws/bolts and remove the lock from the door. If equipped, detach the electrical connectors.

To install:
  1. Attach the electrical connector (if equipped), position the lock assembly to the door and install the retaining screws/bolts. Tighten the screws/bolts to 62 inch lbs. (7 Nm). Do NOT overtighten.
  2. Attach the outside handle to the lock assembly rod.
  3. Connect the lock cylinder to the lock assembly rod.
  4. Connect the inside handle to the lock rod and inside locking rod.
  5. Fasten the water deflector.
  6. Install the inside door trim panel.

----------------

fghgbkj

max