Front Side Door Outer Panel Replacement
Warning:Refer toApproved Equipment for Collision Repair Warning.
Note:Before beginning the repair, refer toMetal Panel Bondingfor proper adhesiveapplicator preparations and general information.Disconnect the negative battery cable. Refer toBattery Negative Cable Disconnection and Connection.Disable the SIR system. Refer toSIR Disabling and Enabling.Remove all related panels and components.Repair as much of the damage as possible to factoryspecifications. Refer toDimensions - Body.Remove the door assembly. Refer toFront Side Door Replacement.
Locate and drill out all factory welds. Note the number andlocation of welds for installation of the service panel.
Grind the edges of the door outer panel to separate the outerdoor panel from the door shell.
Warning:Inspection of the door guard beam for damage must beperformed before replacement of the door outer panel. If damage tothe door guard beam is found the door must be replaced. Failure todo so may compromise the structural integrity of the vehicle andmay cause personal injury if the vehicle is involved in acollision.Remove the outer door panel.Remove the sealers and anti-corrosion materials from therepair area, as necessary. Refer toAnti-Corrosion Treatment and Repair.Straighten the edges of the door shell.Installation Procedure
Using a grinding disk grind the surface of the door shellmating flanges to bare steel.
Scuff the opposing mating surfaces of the door outer panel toremove the gloss of the E-Coat.
Drill 8-mm (5/16-in) plug weld holes,as necessary, in the locations noted from the originalpanel.
Note:In any area damaged beyond recognition, space plug weld holesevery 40-mm (1-in) apart.Clean the mating surfaces.
Note:Do not allow the door to totally cure off the vehicle, asproper alignment of the door outer panel to the door shell will bedifficult.Apply a 3–6-mm(1/8–1/4-in) bead of metal panel bondingadhesive to both of the mating surfaces.Using a small acid brush, spread a coat of adhesive to coverall the bare metal surfaces to ensure corrosion protection.Apply a 9–13-mm(3/8–1/2-in) bead of metal bonding adhesive tothe mating surfaces of the service panel.
Note:Do NOT pull the panels apart after being joined together.Slide the panels against each other to realign the panels.Install the door outer panel to the door shell.Clamp the door outer panel into position, as required.
Using a hammer re-hem the hem flanges around the doorshell.
Continue to hammer in stages along the hem flanges.Using lacquer thinner remove the excess adhesive from thedoor panel area.Install the door to the vehicle. Inspect the door outer panelfor proper alignment; then adjust the alignment, as required. RefertoFront Side Door Replacement.
Using metal-inert gas (MIG), weld the door outer panel to thedoor frame in the locations noted at the upper door frame.Clean and prepare all welded surfaces.
Apply Fusor super flexible anti-flutter foam-fast set, FusorP/N-121/124, or equivalent, in a continuous bead theentire length between the beltline reinforcement and the door outerpanel.Apply Fusor super flexible anti-flutter foam-fast set, FusorP/N-121/124, or equivalent, in a continuous bead theentire length between the door outer panel and the inner safetybeam making multiple passes behind the side impact sensor portionof the beam as required to fill in any gaps.Paint the repaired area. Refer toBasecoat/Clearcoat Paint Systems.Install all related panels and components.Enable the SIR system. Refer toSIR Disabling and Enabling.Connect the negative battery cable. Refer toBattery Negative Cable Disconnection and Connection.