Cruze

Rear Side Door Outer Panel Replacement - MIG-Brazing

Special Tools

For equivalent regional tools, refer to Special Tools .

Note : According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Warning : Refer to Glass and Sheet Metal Handling Warning in the Preface section.

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the rear side door. Refer to Rear Side Door Replacement .
4. Remove the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement .
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .



6. Grind the edges of the rear side door outer panel to separate the outer door panel from the door shell.



7. Remove the rear side door outer door panel.
8. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
9. Straighten the edges of the door shell.

1. Apply structural adhesive on the flanges of the rear side door inner panel where the rear side door outer panel bears on.
2. Align the rear side door outer panel.
3. Verify the fit of the rear side door outer panel.



4. Clamp the rear side door outer panel into position.
5. Pre-flanging the flange with BO-6396 pliers and BO-6392 tool kit.



6. Continue to hammer in stages along the hem flanges.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair : Base .
8. Install the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement .
9. Install the rear side door. Refer to Rear Side Door Replacement .
10. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Enable the SIR system. Refer to SIR Disabling and Enabling .