GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Malibu 🢒 Body 🢒 Collision Repair 🢒 Rear Side Door Outer Panel Replacement

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.

    Caution: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection , earplugs, welding gloves, and protective clothing.

    Caution: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection , earplugs, welding gloves, and protective clothing.

    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. Caution: Refer to SIR Caution in the Preface section.

  2. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  3. Remove the door from the vehicle. Refer to Front Side Door Replacement or to Rear Side Door Replacement .
  4. Remove the outer door handle. Refer to Door Outside Handle Replacement .

    5. Object Number: 1203508 Size: SH
  5. Locate and drill out all factory welds. Note the number and location of welds.

    6. Object Number: 1203512 Size: SH
  6. Grind the edges of the door outer panel to separate the outer door panel from the door shell.

    7. Object Number: 1203516 Size: SH

    Caution: 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.

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

    9. Object Number: 1203525 Size: SH
  9. Straighten the edges of the door shell.

Installation Procedure

    Object Number: 1203528 Size: SH
  1. Using a grinding disk grind the surface of the door shell mating flanges to bare steel.

    2. Object Number: 1203540 Size: SH
  2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat.

    3. Object Number: 1203584 Size: SH
  3. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panel.

    4. Important: If the location of the original plug welds can not be determined, space the plug weld holes every 40 mm (1 in) apart.

  4. Clean the mating surfaces.

    5. Object Number: 1203587 Size: SH

    Important: 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.

  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 bare metal surfaces to ensure corrosion protection.

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


    Object Number: 1203516 Size: SH
  7. Install the door outer panel to the door shell.
  8. Clamp the door outer panel into position as required.

    9. Object Number: 1203606 Size: SH
  9. Using a hammer re-hem the hem flanges around the door shell .

    10. 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 check the door outer panel for proper alignment, adjust the alignment as required.

    12. Object Number: 1203609 Size: SH
  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. Object Number: 1203612 Size: SH
  14. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124 or equivalent in 4-5 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/Coatings.
  16. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  17. Install the outer door handle. Refer to Door Outside Handle Replacement .
  18. Remove the door from the vehicle. Refer to Front Side Door Replacement or to Rear Side Door Replacement .
  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.