Avalanche 2500 4WD V8-8.1L VIN G (2003)
1. Repair any damage done to the door during the drilling or the removal of the hinge.
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 an 11.5 mm (29/64 in) hole at the pilot locations.
IMPORTANT: Drill bit must be exact size.
7. Clean and prepare all of the bare metal surfaces.
8. Apply approved anti-corrosion primer.
IMPORTANT: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do
not combine paint systems. Refer to paint manufacturer's recommendations.
9. Apply a full-bodied caulk to the entire hinge mounting surface in order to ensure a proper seal.
10. Align the hinge (1) and the backing plate (4) with the holes in the door (2) and install the bolts (3)
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the bolts to 25 N.m (18 lb ft).
11. Apply the sealers.
12. Refinish the metal surfaces as necessary.
13. Install and align all of the related panels and the components.
