GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2007 🢒 ION 🢒 Body Systems 🢒 Vehicle Access 🢒 Front Side Door Outer Panel Replacement

Removal Procedure
  1. Remove the front mirror assembly. Refer to Outside Rearview Mirror Replacement .
  2. Remove the outside door release handle. Refer to Door Outside Handle Replacement .
  3. Remove the outer belt sealing strip. Refer to Front Side Door Window Outer Sealing Strip Replacement .

    4. Object Number: 867430 Size: SH
  4. Remove the outer door panel fasteners.
  5. Slide the outer door panel upward to remove the panel.

    6. Object Number: 863949 Size: SH
  6. If the panel is being replaced, use a flat-bladed tool to remove the door lock cylinder bezel and the U-nuts.

Installation Procedure

    Object Number: 863949 Size: SH
  1. If the panel is being replaced, install the following components:
    2. 1.1. Slide the U-nuts over the door panel attaching holes.
    1.2. Press the door lock cylinder bezel into the lock cylinder access hole.

    Object Number: 867430 Size: SH
  2. Install the outer door panel alignment pins into the net holes on the door structure.

    3. Object Number: 863951 Size: SH
  3. Apply LOCTITE® Blue, GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the bolts.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. For the sedan only, install the outer door panel fasteners. Tighten in the sequence shown.

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


    Object Number: 863953 Size: SH
  5. For the coupe only, install the outer door panel fasteners. Tighten in the sequence shown.

    6. Tighten
    Tighten the fasteners to 6 N·m (53 lb in).

  6. Install the outer belt sealing strip. Refer to Front Side Door Window Outer Sealing Strip Replacement .
  7. Install the outside door handle. Refer to Door Outside Handle Replacement .
  8. Install the front mirror. Refer to Outside Rearview Mirror Replacement .