Home Auto Repair 2005-2007 Saturn Relay Panel Replacement – Front Door Outer

2005-2007 Saturn Relay Panel Replacement – Front Door Outer


Download Removal Procedure Caution Refer to Approved Equipment for Collision Repair Caution in Cautions and Notices. Important Before beginning the repair, refer to Metal Panel Bonding for proper adhesive applicator preparations and general information. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical. 2. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR. 3. Remove the door from the vehicle. Refer to Door Replacement – Front in Doors. 4. Remove the outer door handle. Refer to Door Handle Replacement – Front Outside in Doors. 5. Remove the outside rear view mirror. Refer to Mirror Replacement – Power in Doors. 6. Locate and drill out all factory welds. Note the number and location of welds at the upper window frame and mirror locations. 7. Grind the edges of the door outer panel to separate the outer door panel from the door shell. 8. Remove the outer door panel. 9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint/Coatings. 10. Straighten the edges of the door shell. Installation Procedure 1. Grind the surface of the door shell mating flanges to bare steel. 2. Scuff the opposing mating surfaces of the door outer panel to remove the gloss of the E-Coat.