GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Uplander - 4WD 🢒 Body 🢒 Collision Repair 🢒 Front Side Door Outer Panel Replacement

Removal Procedure

    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 to Front Side Door Replacement in Doors.
  4. Remove the outer door handle. Refer to Front Side Door Outside Handle Replacement in Doors.
  5. Remove the outside rear view mirror. Refer to Power Mirror Replacement in Doors.

    6. Object Number: 864411 Size: SH
  6. Locate and drill out all factory welds. Note the number and location of welds at the upper window frame and mirror locations.

    7. Object Number: 864417 Size: SH
  7. Grind the edges of the door outer panel to separate the outer door panel from the door shell.

    8. Object Number: 864445 Size: SH
  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/Coatings.

    10. Object Number: 864452 Size: SH
  10. Straighten the edges of the door shell.

Installation Procedure

    Object Number: 873321 Size: SH
  1. Grind the surface of the door shell mating flanges to bare steel.

    2. Object Number: 864458 Size: SH
  2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat.

    3. Object Number: 864411 Size: SH
  3. Drill plug weld holes 8 mm (5/16 in) deep as necessary in locations noted from the original panel.

    4. Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 25.4 mm (1 in) apart.

  4. Prepare all mating surfaces as necessary.
  5. Apply 3M® Weld-Thru coating P/N 05916 or equivalent to all mating surfaces

    6. Object Number: 864493 Size: SH

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

  6. 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.
  7. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.
  8. Apply a 9-13 mm (3/8 to 1/2 in) bead of metal panel bonding adhesive GM P/N 12378566/7 (Canadian P/N 88901674/5) or equivalent to the service part mating surfaces.

    9. Object Number: 864496 Size: SH

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

  9. Install the door outer panel to the door shell.
  10. Clamp the door outer panel into position as required.

    11. Object Number: 864499 Size: SH
  11. Using a hammer re-hem the hem flanges around the door shell .

    12. Continue to hammer in stages along the hem flanges.

  12. Using lacquer thinner remove the excess adhesive from the door panel area.
  13. Install the door to the vehicle. Inspect the door outer panel for proper alignment and adjust the alignment as required. Refer to Front Side Door Replacement in Doors.
  14. Remove the door from the vehicle to complete the repair.

    15. Object Number: 864515 Size: SH
  15. Metal-inert gas (MIG) weld the door outer panel to the door frame in the locations noted at the upper door frame.
  16. Clean and prepare all welded surfaces.

    17. Object Number: 864502 Size: SH
  17. 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.
  18. Apply sealers and anti-corrosion materials to the repair area as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings.
  19. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint/Coatings.
  20. Install the door to the vehicle. Inspect the door outer panel for proper alignment and adjust the alignment as required. Refer to Front Side Door Replacement in Doors.
  21. Install the outer door handle. Refer to Front Side Door Outside Handle Replacement in Doors.
  22. Install the outside rear view mirror. Refer to Power Mirror Replacement in Doors.
  23. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.