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Front Side Door Outer Panel Replacement

Front Side Door Outer Panel Replacement

Removal Procedure

Refer to Approved Equipment for Collision Repair Warning .

Refer to Glass and Sheet Metal Handling Warning .

Note

Before beginning the repair, refer to Metal Panel Bonding for proper adhesive applicator preparations and general information.



1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling .

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

3. Remove all related panels and components.

4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body .

5. Remove the door assembly. Refer to Front Side Door Replacement .

6. Find all factory welds and drill them out (1). Note the number of welding points and placement at the top window frame and the mounting points of the door mirrors.


7. Grind the edges of the door outer panel to separate the outer door panel from the door shell (1).


8.
Warning

Inspection of the door guard beam for damage must be performed before replacement of the door outer panel. If damage to the door guard beam is found the door must be replaced. Failure to do so may compromise the structural integrity of the vehicle and may cause personal injury if the vehicle is involved in a collision.


Remove the outer door panel (1).


9. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

10. Straighten the edges of the door inner panel (1).



Installation Procedure


1. Grind the door body surface with an abrasive disc to remove all adhesive (1). Align the flanges to the outer panel.


2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat (1).


3.
Note

If the location of the original plug welds cannot be determined or structural weld- thru adhesive was present, space plug weld holes every 40 mm (1 1/2 in) apart.


Drill 8 mm (5/16 in) plug weld holes as necessary in locations noted from the original panel (1).


4. Clean the mating surfaces.

5.
Note

The adhesive has a 40-50 minute working time. Do not allow the door to totally cure off the vehicle, as proper alignment of the door outer panel to the door shell will be difficult.


Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive to both of the mating surfaces (1).


6. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.

7. Install the door outer panel to the door shell (1).


8.
Note

Do NOT pull the panels apart after being joined together. Slide the panels against each other to realign the panels.


Clamp the door outer panel into position as required (1).


9. Using a hammer re-hem the hem flanges around the door shell (2).

Continue to hammer in stages along the hem flanges.

10. Using lacquer thinner remove the excess adhesive from the door panel area.

11. Install the door to the vehicle. Inspect the door outer panel for proper alignment, adjust the alignment as required.

12. Using metal-inert gas (MIG), weld the door outer panel to the door frame in the locations noted at the upper door frame (1).


13. Clean and prepare all welded surfaces.

14. Apply anti-flutter foam at 4-5 evenly spaced points between the door's outer panel and side-impact reinforcement (1).


15. Apply sealers and anti-corrosion materials to the repair area, as necessary.

16. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems .

17. Install the door assembly. Refer to Front Side Door Replacement .

18. Install all related panels and components.

19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

20. Activate the SIR system. Refer to SIR Disabling and Enabling .