#98-T-13 - Replacement of Interior Door Panel Inserts - (Jan 13, 2003)

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Subject:
New Service Procedure for Replacement of Interior Door Panel Inserts
Models:
1996–1998 Saturn Sedans and Wagons, and 1997–1998 Saturn Coupes
Purpose:

The purpose of this bulletin is to communicate a new service procedure when replacing the interior door panel. The door panel and...

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Document Title: #98-T-13 - Replacement of Interior Door Panel Inserts - (Jan 13, 2003)

procedure

interior

door

panel

insert

coupe

trim

energy

absorbing

foam

from

vehicle

fmvss

remove

mirror

pulling

disengage

attaching

equipped

manual

allow

right

shown

fastener

center

inside

handle

assembly

slide

forward

outward

using

thin

lock

latch

power

switch

window

tool

regulator

clip

proper

angle

lower

rear

corner

structure

hooks

place

heat

staked

work

bench

cloth

type

material

sedan

similar

important

drill

stud

substrate

round

rectangle

hand

grinder

diameter

grinding

equivalent

stake

press

weld

steady

pressure

onto

remaining

install

position

panel door

door trim

trim panel

remove door

panel remove

mirror trim

inside door

door handle

power door

manual window

window regulator

regulator handle

handle clip

window handle

angle right

right manual

angle manual

panel assembly

door structure

structure attaching

attaching hooks

place door

sedan panel

panel shown

shown coupe

coupe panel

panel similar

round heat

door insert

insert door

heat stake

stake material

panel substrate

press door

stake weld

remaining door

install door

position door

handle install

door lock

power window

door panel door

panel door panel

interior door trim

door trim panel

caution disturb energy

disturb energy absorbing

absorbing foam time

foam time during

procedure energy absorbing

absorbing foam removed

foam removed door

trim panel replaced

from door door

door door trim

trim panel vehicle

panel vehicle meet

vehicle meet federal

motor vehicle safety

vehicle safety standards

safety standards fmvss

standards fmvss subjecting

fmvss subjecting retailer

possible civil penalties

civil penalties making

penalties making vehicle

making vehicle inoperative

fmvss increasing risk

increasing risk injury

risk injury vehicle

remove door trim

trim panel remove

mirror trim panel

trim panel left

panel left only

mirror insulator right

insulator right shown

right shown typical

remove fastener center

center inside door

inside door handle

slide door handle

door handle assembly

handle assembly forward

assembly forward pulling

forward pulling outward

from trim panel

using thin screwdriver

thin screwdriver disengage

screwdriver disengage lock

remove inside door

manual window vehicles

window vehicles using

vehicles using standard

disengage manual window

manual window regulator

window regulator handle

regulator handle clip

handle clip remove

proper angle right

angle right manual

right manual window

proper angle manual

angle manual window

trim panel fasteners

pull door trim

trim panel assembly

panel assembly disengage

assembly disengage trim

panel door structure

door structure attaching

structure attaching hooks

attaching hooks remove

hooks remove door

place door trim

trim panel heat

panel heat staked

type material protect

material protect panel

sedan panel shown

panel shown coupe

shown coupe panel

coupe panel similar

important drill heat

drill heat staked

heat staked stud

staked stud stud

material substrate door

substrate door trim

round heat staked

heat staked studs

remove rectangle shaped

rectangle shaped heat

shaped heat stakes

diameter grinding disk

equivalent grinding studs

door insert door

insert door trim

remove heat stake

heat stake material

stake material door

trim panel holes

panel holes door

holes door trim

trim panel substrate

installation procedure center

panel assembly cloth

assembly cloth type

protective material heat

material heat stake

side work bench

door insert corners

press door insert

door insert heat

insert heat stake

heat stake door

stake door trim

panel substrate important

substrate important desirable

important desirable round

desirable round heat

round heat stake

heat stake weld

stake weld approximate

desired rectangle heat

stake weld approximately

using weller model

weller model soldering

equivalent equipped flat

circular motion around

heat stake apply

stake apply firm

apply firm steady

firm steady pressure

steady pressure spread

pressure spread heat

stake material onto

material onto door

onto door trim

panel substrate achieve

proper weld sedan

weld sedan panel

after heat stake

heat stake melted

stake melted steady

melted steady pressure

door insert hand

insert hand seconds

hand seconds allow

heat stake harden

remaining door insert

continue press door

panel substrate heat

substrate heat stake

heat stake remaining

stake remaining door

verify door insert

door insert securely

insert securely heat

securely heat staked

panel substrate locations

substrate locations install

locations install door

install door trim

trim panel position

panel position door

position door trim

hooks lock door

lock door trim

trim panel pushing

panel pushing downward

door trim fasteners

lower corner door

corner door trim

window vehicles install

vehicles install manual

install manual window

handle clip handle

clip handle install

handle install door

install door handle

door handle onto

vehicle handle pointed

position window closed

power door lock

handle assembly trim

assembly trim panel

using thin hook

thin hook style

hook style tool

style tool lift

latch lock rods

lock rods trim

rods trim panel

trim panel slide

panel slide rearward

rear door trim

equipped remove power

power window switch

window switch door

power window electrical

equipped install power