GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Body and Accessories 🢒 Collision Repair 🢒 Panel Assembly - Side Door Ring Outer Replacement

    Object Number: 861880 Size: MF
  1. Remove the sealer.
  2. Drill the spot welds from:
    3. 2.1. The panel assembly-center pillar
    2.2. The upper panel assembly-rocker outer
    2.3. The rail assembly-rear compartment side upper
    2.4. The panel assembly-quarter rear
    2.5. The panel assembly-quarter inner lower front
    2.6. The reinforcement-quarter inner panel lower
  3. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
  4. Apply a permanent underbody sealant.

    5. Important: Ensure that proper corrosion protection processes are used on all repair areas.

  5. Prime with a 2-part catalyzed primer.
  6. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
  7. Clean the surface for welding and grind the primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
  8. Measure and align the panel assembly side door ring outer. Clamp into place.
  9. Use a MIG to plug the weld.
  10. After installing the new part, apply 3M® Ultrapro Urethane Seam Sealer P/N 08361, or equivalent, around the baffles.