GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 ION 🢒 Body 🢒 Doors 🢒 Front Side Door Outer Panel Replacement

Removal Procedure
  1. Remove the front mirror assembly. Refer to Outside Rearview Mirror Replacement .
  2. Remove the outside door release handle. Refer to Door Outside Handle Replacement .
  3. Remove the outer belt sealing strip. Refer to Front Side Door Window Outer Sealing Strip Replacement .

    4. Object Number: 867430 Size: SH
  4. Remove the outer door panel fasteners.
  5. Slide the outer door panel upward to remove the panel.

    6. Object Number: 863949 Size: SH
  6. If the panel is being replaced, use a flat-bladed tool to remove the door lock cylinder bezel and the U-nuts.

Installation Procedure

    Object Number: 863949 Size: SH
  1. If the panel is being replaced, install the following components:
    2. 1.1. Slide the U-nuts over the door panel attaching holes.
    1.2. Press the door lock cylinder bezel into the lock cylinder access hole.

    Object Number: 867430 Size: SH
  2. Install the outer door panel alignment pins into the net holes on the door structure.

    3. Object Number: 863951 Size: SH
  3. Apply Locktite® Blue, GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the bolts.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. For the sedan only, install the outer door panel fasteners. Tighten in the sequence shown.

    5. Tighten
    Tighten the fasteners to 6 N·m (53 lb in).


    Object Number: 863953 Size: SH
  5. For the coupe only, install the outer door panel fasteners. Tighten in the sequence shown.

    6. Tighten
    Tighten the fasteners to 6 N·m (53 lb in).

  6. Install the outer belt sealing strip. Refer to Front Side Door Window Outer Sealing Strip Replacement .
  7. Install the outside door handle. Refer to Door Outside Handle Replacement .
  8. Install the front mirror. Refer to Outside Rearview Mirror Replacement .