Outer Door Panel: Installation

1. If replacing panel: Install clip and trim molding. Install J-Clips. Install door lock cylinder bezel. Install outer door panel lower sealing strip with rivets.
2. Install foam tape fillers at front edge of outer door panel. Using Kent Industries P/N 40130 1/2" x 9/16" or equivalent cut to length and align foam tape to scribe lines on outer door panel for the following:

   1. Sedan & Wagon
      
      A = 1.97" (50 mm), B = 4.72" (120 mm), on piece "B" trim 0.197" (5 mm) of thickness from area indicated by arrow. See Fig 1 .
   2. Coupe
      
      A = 3.54" (90 mm), B = 1.97" (50 mm) and C = 5.31" (135 mm).
3. Install foam tape damper in middle of outer door panel using Kent Industries 40140 3/4" x 7/16" or equivalent cut length and align to scribe lines in center of back side of panel for the following:

   1. Sedan & Wagon
      
      C = 15.75" (400 mm) length.
   2. Coupe
      
      D = 19.69" (500 mm) Length; E = 3.94" (100 mm) length.
4. If removed, install foam seal strip to perimeter of door structure using Kent Industries P/N 40405 1/4" x 5/32" or equivalent.
5. Install outer door panel alignment puns into net hole and slot in outer belt reinforcement (door structure). See Fig 2 .
6. On Sedan and Wagon models, install 10 screws and tighten in designated sequence. Tighten to 53 INCH lbs. (6 N.m).
7. On Coupe models, install 11 screws and tighten in designated sequence.
8. On all models, install door handle by lifting pivot assembly and sliding handle on pivot and inserting pushpins.
9. Install outer sealing strip by aligning location tab at rear of sealing strip slot in door panel. Working from the rear forward, push seal strip down on to flange until fully seated. See Fig 3 .
10. Check seal on mirror assembly for proper location and install nuts and tighten. Tighten to 53 INCH lbs. (6 N.m).
11. If passenger side power mirror connects harness connector, install Connector Position Assurance (CPA) device.
12. Install foam filler in mirror patch area.
13. On driver side, install mirror cable into trim panel and tighten set screw. Tighten to 27 INCH lbs. (3 N.m).
14. Install trim panel to door frame with screw and tighten.
15. Install removed portion of window frame garnish by pushing to seat in channel.

Fig 1: Installing Outer Door Panel (1 Of 3)

Courtesy of GENERAL MOTORS CORP.

Fig 2: Installing Outer Door Panel (2 Of 3)

Courtesy of GENERAL MOTORS CORP.

Fig 3: Installing Outer Door Panel (3 Of 3)

Courtesy of GENERAL MOTORS CORP.