Tools You'll Likely Need:
* Socket set and wrenches: Various sizes will be needed for the bolts securing the hinge and possibly the door panel.
* Screwdrivers: Phillips and flathead, likely.
* Punch or pry bar: To help dislodge pins or rusted bolts.
* Penetrating oil (PB Blaster or similar): To loosen rusted bolts.
* Jack and jack stands (or ramps): To safely support the vehicle.
* Safety glasses and gloves: Essential for protection.
* New hinge(s): Obtain the correct replacement hinge for your Aveo's year and model.
* Torque wrench: Crucial for tightening bolts to the manufacturer's specifications.
* Door alignment tool (optional but helpful): Makes aligning the door after reinstallation easier.
General Steps (Consult your repair manual for specifics):
1. Preparation: Disconnect the negative battery terminal. Raise and securely support the vehicle using jack stands. Remove the interior door panel. This usually involves removing screws and carefully prying the panel away from the door.
2. Access the Hinge: The hinge will be attached to both the door and the body of the vehicle with bolts. You may need to remove some trim pieces for better access.
3. Remove the Hinge: Carefully remove the bolts securing the hinge to the door and the body. Penetrating oil may be necessary to loosen rusted or stubborn bolts. Work methodically, keeping track of the hardware. There may be pins or bushings involved, which may require a punch or pry bar to remove.
4. Install the New Hinge: Carefully align the new hinge with the corresponding mounting holes on the door and the body. Install the bolts, ensuring proper alignment. Do not overtighten.
5. Reassemble: Reinstall the door panel and any removed trim pieces. Lower the vehicle.
6. Door Alignment: This is crucial. The door may not align perfectly after replacing the hinge. You may need to adjust the door's position slightly by loosening and tightening bolts on the remaining hinges. A door alignment tool can help significantly.
7. Test: Open and close the door several times to ensure smooth operation and proper alignment. Reconnect the negative battery terminal.
Important Considerations:
* Rust: If the old hinge is rusted, removing the bolts can be difficult. Use penetrating oil liberally and allow it to soak in for a while.
* Bolts: Keep track of all the bolts and their locations. Using the wrong-size bolts or installing them in the wrong places can cause damage.
* Torque Specifications: Always consult your repair manual for the correct torque specifications for all the bolts. Overtightening can strip the threads or damage the hinge.
* Professional Help: If you're not comfortable performing this repair yourself, it's best to take your Aveo to a qualified mechanic. Improper repair can lead to safety hazards.
This is a simplified overview. The exact steps and procedures will vary depending on the year and model of your Chevy Aveo. Always refer to a repair manual specific to your vehicle before starting this repair. A Haynes or Chilton manual would be a good investment for future repairs.
