Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

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

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
3. Remove the door from the vehicle. Refer Front Side Door Replacement in Doors.
4. Remove the outer door handle. Refer to Door Outside Handle Replacement in Doors.
5. Remove the outside rear view mirror. Refer to Power Mirror Replacement in Doors.



6. Locate and drill out all factory welds. Note the number and location of welds at the upper window frame and mirror locations.



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



8. Remove the outer door panel.
9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.



10. Straighten the edges of the door shell.

1. Using a grinding disk grind the surface of the door shell mating flanges to bare steel.



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



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

Important: If the location of the original plug weld holes can not be determined, space the plug weld holes 40 mm (1½ in) apart.

4. Clean the mating surfaces.




Important: The adhesive has a 40 to 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.

5. Apply a 3-6 mm (1/8 to 1/4 in) bead of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5) or equivalent, to both of the mating surfaces.
6. Using a small acid brush, spread a coat of adhesive to cover all the mating surfaces to ensure corrosion protection.

Important: DO NOT pull the panels apart after joined together. Slide the panels against each other to realign the panels.




7. Install the door outer panel to the door shell.
8. Clamp the door outer panel into position as required.



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

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. Refer Front Side Door Replacement in Doors.



12. Metal-Inert Gas (MIG) weld the door outer panel to the door frame in the locations noted at the upper door frame.
13. Clean and prepare all welded surfaces.



14. Apply Fusor super flexible anti-flutter foam fast set, Fusor P/N 121/124, or equivalent in 4 to 5 evenly spaced locations between the door outer panel and the inner safety beam.
15. Apply sealers and anti-corrosion materials to the repair area as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
16. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
17. Install the outer door handle. Refer to Door Outside Handle Replacement in Doors.
18. Install the outside rear view mirror. Refer to Power Mirror Replacement in Doors.
19. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.