GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Body and Accessories 🢒 Doors 🢒 Outer Door Panel Replacement Front - Bolt On

Removal Procedure

    Object Number: 864741 Size: SH
  1. Remove the front door mirror assembly. Refer to Power Mirror Replacement removal procedure.

    2. Object Number: 864366 Size: SH
  2. Remove the door outside handle.
  3. Lift the handle and remove the push pin.

    4. Object Number: 894101 Size: SH
  4. Slide the door handle to remove from the pivot assembly.

    5. Object Number: 893608 Size: SH
  5. Remove the outer belt seal. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement removal procedure.

    6. Object Number: 883086 Size: SH
  6. Remove the outer door panel fasteners.

    7. Important: Use masking tape to hold the outer panel in place while removing the screws.

  7. Remove the outer door panel from the structure by pulling slightly outward at the bottom and sliding upward.

    8. Object Number: 897839 Size: SH
  8. If replacing the panel:
    9. 8.1. Remove the door lock cylinder bezel.
    8.2. Remove the U-nuts.

Installation Procedure

    Object Number: 897839 Size: SH
  1. If replacing the panel:
    2. 1.1. Install the U-nuts.
    1.2. Install the door lock cylinder bezel.

    Object Number: 883086 Size: SH
  2. Install the outer door panel alignment pins on the outer panel into the slot in the outer reinforcement -- door structure.

    3. Object Number: 893706 Size: SH
  3. Install the outer belt seal. Refer to Front Side Door Window Belt Outer Sealing Strip Replacement installation procedure .
    4. 3.1. Align the outer belt seal with the slot in the outer door panel.
    3.2. Working from the rear, push the outer belt seal down onto the flange until fully seated.

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 893709 Size: SH

    Important: Use LOCTITE 242® Threadlocker, or equivalent, on the nuts before installation.

  4. Install the outer door panel fasteners and tighten in the designated sequence.

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


    Object Number: 894101 Size: SH
  5. Install the door outside handle.
  6. Slide the handle onto the pivot assembly.

    7. Object Number: 864366 Size: SH
  7. Lift the door handle and install the push pin.

    8. Object Number: 864741 Size: SH
  8. Install the front door mirror assembly. Refer to Outside Rear View Mirror installation procedure .