GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Daewoo 🢒 2008 🢒 G2X 🢒 Body Repair 🢒 Collision Repair 🢒 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 .
  2. Disable the SIR system. Refer to SIR Disabling and Enabling .
  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. Object Number: 1780757 Size: SH
  6. Grind the edges of the door outer panel to separate the outer door panel from the door shell.

    7. Object Number: 1780759 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.

    Important: Do not damage the upper belt reinforcement when removing the outer door panel.

  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 .
  9. Straighten the edges of the door shell.

Installation Procedure

    Object Number: 1780845 Size: SH
  1. Using a grinding disk grind the surface of the door shell mating flanges to bare steel.

    2. Object Number: 1780864 Size: SH
  2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat.
  3. Clean the mating surfaces.

    4. Object Number: 1780877 Size: SH

    Important: Do not allow the adhesive to totally cure off the vehicle, as proper alignment of the door outer panel to the door shell will be difficult.

  4. Apply a 3-6 mm (1/8-1/4 in) bead of metal panel bonding adhesive to both of the mating surfaces.
  5. Using a small acid brush, spread a coat of adhesive to cover all the bare metal surfaces to ensure corrosion protection.
  6. Apply a 9-13 mm (3/8-1/2 in) bead of metal panel bonding adhesive to the mating surfaces of the service panel.

    7. Object Number: 1780915 Size: SH

    Important: Anti-flutter foam must be applied to the upper belt reinforcement prior to installing the outer door panel.

  7. Apply anti-flutter foam in the areas noted from the original panel.

    8. Object Number: 1780754 Size: SH

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

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

    10. Object Number: 1780948 Size: SH
  10. Using a hammer re-hem the hem flanges around the door shell .

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

  11. Using lacquer thinner remove the excess adhesive from the door panel area.
  12. Install the door to the vehicle. Inspect the door outer panel for proper alignment, then adjust the alignment, as required.
  13. Apply sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  14. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  15. Install the door assembly. Refer to Front Side Door Replacement .
  16. Install all related panels and components.
  17. Enable the SIR system. Refer to SIR Disabling and Enabling .
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .