1. Preparation:
* Safety First: Disconnect the negative battery terminal. Wear safety glasses and gloves.
* Gather Tools: You'll need a variety of tools, including sockets, wrenches, screwdrivers (Phillips and flathead), a torque wrench, pliers, possibly a rivet gun or drill, and potentially a body hammer and dolly for minor bodywork adjustments. A service manual is crucial.
* Parts: Obtain a replacement driver's side door. Ensure it's the correct year and model. You may also need new weatherstripping, window regulators (if damaged), door handle mechanisms, and other related hardware depending on the condition of the old door.
* Workspace: Work in a well-lit, clean area with ample space.
2. Door Removal:
* Interior Panel Removal: Carefully remove the interior door panel. This involves removing screws, clips, and possibly detaching the window crank or power window switch. Consult your repair manual for the precise method.
* Disconnect Wiring Harness: Unplug all electrical connectors from the door: power windows, door locks, courtesy lights, speakers, etc. Take pictures or label the connectors to ensure proper reconnection.
* Disconnect Mechanical Linkages: Disconnect the door lock linkage, window regulator cables, and exterior door handle mechanisms.
* Remove Door Hinge Bolts: Remove the bolts securing the door to the hinges on both the door and the vehicle body. These are usually located at the top and bottom of the door. You might need to maneuver the door slightly to access all the bolts.
* Lower the Door: Carefully lower the door to the ground. Have a helper assist to prevent damage.
3. Door Installation:
* Prepare the New Door: If necessary, install new weatherstripping and other parts onto the new door.
* Align the Door: Carefully align the new door with the hinges on the vehicle body.
* Install Hinge Bolts: Install the hinge bolts and tighten them securely, but do not overtighten. Refer to your repair manual for torque specifications.
* Reconnect Mechanical Linkages: Reconnect the door lock linkage, window regulator cables, and exterior door handle mechanisms.
* Reconnect Wiring Harness: Reconnect the electrical connectors, ensuring everything is plugged in correctly.
* Install Interior Panel: Reinstall the interior door panel.
4. Adjustment and Testing:
* Door Alignment: Adjust the door to ensure it closes properly and aligns correctly with the body. This might involve slight adjustments to the hinge bolts.
* Functionality Test: Test all door components: window operation, door locks, power features.
* Final Tightening: Perform a final tightening of all bolts and connections.
Important Considerations:
* Repair Manual: A factory service manual is absolutely essential for this job. It will provide detailed diagrams, torque specifications, and critical steps to avoid damage.
* Bodywork: If the old door was damaged extensively, you might need to do some minor bodywork to ensure the new door fits correctly.
* Professional Help: If you're not comfortable with this level of auto repair, it's strongly recommended to take your Suburban to a qualified mechanic. This is a complex job, and mistakes can be costly.
This is a simplified overview. Refer to a 1994 Chevrolet Suburban repair manual for detailed, step-by-step instructions and diagrams before attempting this repair. Remember, safety is paramount.
