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

Front Side Door Outer Panel Coupe

Removal Procedure

    Object Number: 864741 Size: SH
  1. Remove the front door mirror assembly. Refer to Outside Rearview Mirror Replacement .

    2. Object Number: 864366 Size: SH
  2. Pry the center part of the plastic retainer of the outer handle out. Pull the retainer out of the handle.

    3. Object Number: 864674 Size: SH
  3. Slide the handle off the pivot assembly and remove the handle.

    4. Object Number: 883086 Size: SH
  4. Remove the fastener at the rear of the window outer sealing strip (belt seal). Remove the sealing strip.

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

  5. Remove the outer door panel screws.
  6. Remove the outer door panel from the structure by sliding upward.

    7. Object Number: 865859 Size: SH
  7. If replacing the panel:
    8. • Remove the door lock cylinder bezel.
    • Remove the U-nuts.

Installation Procedure
  1. If replacing the panel:
    2. • Install the U-nuts.
    • Install the door lock cylinder bezel.

    Object Number: 883086 Size: SH

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

  2. Install the outer door panel alignment pins into the net hole and slot in the outer belt reinforcement (door structure).

    3. Object Number: 866324 Size: SH
  3. Install the outer sealing (belt seal) strip by aligning the location tab at the rear of the sealing strip with the slot in the door panel. Working from the rear forward, push the seal strip down onto the flange until fully seated. Install the fastener.

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


    Object Number: 864712 Size: SH

    Important: Apply Loctite 242® Threadlocker, or equivalent, to the fasteners before installation.

  4. Install the fasteners and tighten in the designated sequence.

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


    Object Number: 864674 Size: SH
  5. Install the door handle by lifting the pivot assembly and sliding the handle on the pivot.

    6. Object Number: 864366 Size: SH
  6. Install the plastic retainer.

    7. Object Number: 864741 Size: SH
  7. Install the front door mirror assembly. Refer to Outside Rearview Mirror Replacement .

    8. Tighten
    Tighten the outside rear view mirror nuts to 10 N·m (89 lb in).

Front Side Door Outer Panel Sedan/Wagon

Removal Procedure

    Object Number: 869288 Size: MH
  1. Remove the mirror trim panel. Gently pull the panel outward to disengage.
    2. • Mirror trim panel.
    • Mirror insulator (right side shown, left typical).
  2. On the driver's side, loosen the set screw and disconnect the cable from the trim panel.
  3. Remove the trim panel.
  4. Remove the foam filler from the mirror reinforcement area.
  5. On the passenger side power mirror, disconnect the harness connector.

    6. Object Number: 864741 Size: SH
  6. Remove the nuts from the mirror assembly and remove the mirror and seal.

    7. Object Number: 861270 Size: SH
  7. Remove the retaining screw and the rear of the outer seal strip.
  8. Disengage the outer seal strip by pulling up at the rear end and lifting. Use of a putty knife with a blade covered with tape may be needed to gently pry the sealing strip from the flange. Remove the seal.

    9. Object Number: 864366 Size: SH
  9. Pry the center part of the plastic retainer of the outer handle out. Pull the retainer out of the handle.

    10. Object Number: 864674 Size: SH
  10. Slide the handle off of the pivot assembly and remove the handle.

    11. Object Number: 864714 Size: SH
  11. Remove the door panel screws and remove the door panel.

    12. Object Number: 865859 Size: SH
  12. If replacing the panel:
    13. • Remove the door lock cylinder bezel.
    • Remove the U-nuts.

Installation Procedure
  1. If replacing the panel:
    2. • Install the U-nuts.
    • Install the door lock cylinder bezel.

    Object Number: 869261 Size: MH
  2. Install the outer door panel alignment pins into the net hole and slot in the outer belt reinforcement (door structure).

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


    Object Number: 864707 Size: SH

    Important: Apply Loctite 242® Threadlocker, or equivalent, to the fasteners before installation.

  3. Install the fasteners and tighten in the designated sequence.

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


    Object Number: 864674 Size: SH
  4. Install the door handle by lifting the pivot assembly and sliding the handle on the pivot.

    5. Object Number: 864366 Size: SH
  5. Install the plastic retainer.

    6. Object Number: 861270 Size: SH
  6. Install the outer sealing strip by aligning the location tab at the rear of the sealing strip with the slot in the door panel. Working from the rear forward, push the seal strip down onto the flange until fully seated. Install the retaining screw.

    7. Object Number: 864610 Size: SH
  7. Check the seal on the mirror assembly for proper location.

    8. Object Number: 864741 Size: SH
  8. Install the mirror assembly to the door. Install the nuts and tighten.

    9. Tighten
    Tighten the outside rear view mirror nuts to 10 N·m (89 lb in).


    Object Number: 869288 Size: MH
  9. If equipped with a passenger side power mirror, connect the harness connector and install the connector position assurance (CPA) retainer.
  10. Install the foam filler in the mirror patch area.
  11. On the driver's side, install the mirror cable into the trim panel and tighten the set screw.
    12. • Mirror trim panel.
    • Mirror insulator (right side shown, left typical).

    Tighten
    Tighten the power mirror motor screws to 3 N·m (27 lb in).

  12. Install the trim panel to the door frame. Push to seat.