GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL1/SC1 🢒 Body and Accessories 🢒 Doors 🢒 Rear Side Door Trim Panel Insert Replacement

Removal Procedure

    Object Number: 868423 Size: SH
  1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement .
  2. Replace the door trim panel, heat-staked side up, on a work bench with a cloth-type material to protect the panel's finish.

    3. Object Number: 868427 Size: MH

    Important: Drill into the heat-staked stud just enough to cause the stud material to separate from the substrate (door trim panel) material.

  3. Using a 7 mm (9/32 in) drill bit, drill out the round heat-staked studs.

    4. Object Number: 868928 Size: SH
  4. Remove the old door insert from the door trim panel.
  5. Remove any heat stake material that may be left in the door trim panel holes or on the door trim panel substrate.

Installation

    Object Number: 868423 Size: SH
  1. Center the new door insert on the door trim panel substrate.
  2. Place the door trim panel assembly back on the cloth-type protective material with the heat-stake side up.
  3. Place one hand on the front side of the door trim panel, the side that is on the work bench, at one of the door insert corners. Press and hold the door insert heat stake against the door trim panel substrate.

    4. Object Number: 868430 Size: MH

    Important: A desirable round heat stake weld should have an approximate diameter of 10 mm (13/32 in) and height 2 mm (3/32 in).

  4. Using a Weller® model 8200 soldering gun, or equivalent, equipped with a flat tip, use a circular motion around the heat stake. Apply firm steady pressure to spread the heat stake material onto the door trim panel substrate to achieve a proper weld. Heat stake the door insert to the door trim panel substrate, starting at the four corners of the door insert first.
  5. After the heat stake has been melted, keep steady pressure with your hand on the door insert for 30 seconds, to allow the heat stake to harden.
  6. Repeat Steps 3-5 for the remaining door insert corners.
  7. Continue to press and hold the door insert against the door trim panel substrate and heat stake the remaining door insert studs.
  8. Verify that the door insert is securely heat staked to the door trim panel substrate in all locations.
  9. Install the door trim panel. Refer to Rear Side Door Trim Panel Replacement .