Replacement Door LG Refrigerator Manual

This manual provides comprehensive instructions for the installation, adjustment, and maintenance of replacement doors for LG refrigerators. It covers models with top-mount, bottom-mount, and side-by-side configurations. Below are key sections covering safety precautions, parts identification, step-by-step installation, alignment procedures, troubleshooting, and warranty information.

Parts Overview & Identification

Key components included in the replacement door kit: Door panel (outer shell and inner liner), Hinge covers, Hinge pins and bushings, Gasket (magnetic seal), Handle assembly, Mounting screws and brackets, Door bins/shelves (if applicable), Instruction template.

Safety Precautions

Before beginning installation, review these critical safety guidelines.

1. Unplug the refrigerator from the electrical outlet to prevent electrical shock.
2. Empty the refrigerator and remove all items from doors to reduce weight.
3. Have an assistant help with door handling - doors are heavy and awkward.
4. Work on a clean, flat surface with adequate lighting.
5. Wear safety glasses when drilling or removing hardware.
6. Keep small hardware away from children and pets.

WARNING! Failure to unplug the refrigerator can result in serious electrical injury. The door is heavy and can cause injury if dropped. Always use proper lifting techniques.

Tools Required

Gather these tools before beginning installation:

• Phillips screwdriver: #2 size for most screws
• Flathead screwdriver: For prying and adjusting
• Hex key/Allen wrench set: Metric sizes (included in some kits)
• Adjustable wrench: 10mm for hinge bolts
• Drill with bits: For any required new holes
• Level: 12-inch for door alignment
• Putty knife: For gasket removal/installation
• Soft cloths: For protecting surfaces
• Masking tape: For marking positions

Pre-Installation Checklist

Complete these steps before removing the old door:

1. Verify the replacement door matches your refrigerator model number.
2. Unplug refrigerator and move it away from the wall for access.
3. Remove all food, shelves, and bins from the door being replaced.
4. Take photos of the current hinge configuration for reference.
5. Lay soft blankets or cardboard on floor to protect the door.
6. Have your assistant ready to support the door during removal.
7. Organize hardware in containers to prevent loss.

CAUTION! Do not lay the door flat on its front or back as this may damage the surfaces. Always support it on its edges.

Step-by-Step Installation

Follow these steps in order for proper installation:

1. Remove old door: Support door, remove hinge screws from cabinet, lift door off hinges.
2. Transfer components: Move gasket, bins, and shelves from old door to new door if not included.
3. Install hinges: Attach hinges to new door using provided hardware and template.
4. Hang new door: With assistant, align hinge holes with cabinet, insert hinge pins.
5. Secure hinges: Install and tighten all hinge screws to cabinet.
6. Install gasket: Starting at top corners, press gasket into channel around door perimeter.
7. Attach handle: Position handle, secure with screws, install decorative end caps.
8. Install hinge covers: Snap plastic covers over hinge mechanisms.

Tip: Do not fully tighten hinge screws until after alignment is verified in next section.

Door Alignment & Adjustment

Proper alignment ensures good seal and smooth operation:

1. Check level: Place level on top of door - adjust until bubble is centered.
2. Vertical alignment: Door should be parallel to refrigerator cabinet with even gaps.
3. Horizontal adjustment: Loosen hinge screws, shift door left/right, retighten.
4. Height adjustment: Adjust leveling feet at refrigerator base if door is too high/low.
5. Door swing test: Open door 90° - it should stay open; close smoothly without binding.
6. Gap measurement: Ensure consistent ¼-inch gap around entire door perimeter.
7. Final tightening: Once aligned, firmly tighten all hinge screws.

Note: Some models have adjustable hinges with set screws for fine-tuning alignment.

Gasket Installation & Sealing

The magnetic gasket is critical for energy efficiency:

1. Clean surface: Wipe door gasket channel with mild soap and water, dry completely.
2. Start at top: Begin installation at top center, working toward corners.
3. Press firmly: Use putty knife to press gasket lip fully into channel.
4. Corners: Miter corners neatly without stretching or twisting gasket.
5. Check seal: Close door on dollar bill - should have slight resistance when pulled.
6. Heat treatment: If gasket is stiff, use hair dryer on low to warm and soften.
7. Final inspection: Ensure no gaps, twists, or sections pulled out of channel.

WARNING! Do not cut or trim gasket unless specifically instructed. Stretching can cause premature failure.

Handle & Hardware Attachment

Handle installation varies by model:

1. Position handle using template or existing holes.
2. Insert mounting screws but do not fully tighten.
3. Check handle alignment with level.
4. Tighten screws evenly in crisscross pattern.
5. Install decorative end caps or covers.
6. Test handle for secure attachment.

Testing & Final Checks

After installation, perform these verification steps:

1. Plug in refrigerator and restore power.
2. Check that interior light turns on when door opens.
3. Verify door switch properly controls light and cooling system.
4. Test door seal with paper method at multiple points.
5. Ensure door closes completely without forcing.
6. Check that bins and shelves are securely installed.
7. Verify door doesn't interfere with adjacent cabinets or walls.
8. Run refrigerator for 24 hours and check temperature performance.

CAUTION! Wait at least 4 hours after installation before adding food to allow temperature stabilization.

Care & Maintenance

Proper care extends door life and performance:

• Cleaning: Use mild soap and water with soft cloth; avoid abrasive cleaners.
• Gasket care: Clean monthly with baking soda solution to prevent mildew.
• Hardware check: Tighten hinge screws every 6 months.
• Lubrication: Apply silicone spray to hinge pins annually if door sticks.
• Surface protection: Avoid placing heavy items on door shelves beyond rated capacity.
• Seasonal adjustment: Doors may need slight realignment with temperature/humidity changes.

WARNING! Never use ammonia-based cleaners on gaskets as they cause drying and cracking.

Troubleshooting

Reset: For electronic doors with controls, unplug for 5 minutes to reset system.

Warranty & Support

LG replacement doors are covered by a limited warranty:

• Warranty period: 1 year from date of purchase on parts and labor.
• Registration: Register your product online at www.lg.com for extended support.
• Exclusions: Damage from improper installation, accidents, or unauthorized modifications.
• Service: For warranty claims, contact LG Customer Support at 1-800-243-0000.
• Parts: Genuine LG replacement parts available through authorized dealers.
• Manual updates: Check website for latest installation guides and bulletins.

Support: LG Customer Support: 1-800-243-0000 | www.lg.com | Monday-Friday 8AM-9PM EST