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Home >> Saab >> 2003 >> 9-3 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 31 (Doors & Locks) >> Adjustment - Replacement >> Front door, outer panel

Front door, outer panel

WARNING: This page is about a different car, the 2001 Saab 9-3. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the anti-corrosion sealant so that the welding points become accessible.
  2. Drill out the welds. Take care to only drill in the door panel so that the underlying door frame is not damaged.
    Fig 1: Illustration For Step 2-3
    G03509238Courtesy of SAAB-SCANIA OF AMERICA, INC.
  3. Cut loose the door panel from the door frame as shown in the illustration. Make sure to cut only in the door panel so that the underlying door structure is not damaged.
  4. The door panel is folded over the door structure at the front, rear and lower edges. Grind through the edges so that the door panel releases from the structure.
    Fig 2: Illustration For Step 4-5
    G03509239Courtesy of SAAB-SCANIA OF AMERICA, INC.
  5. Drill out the welds that hold the remaining panel strips on the inside of the door structure.
  6. Detach the door panel from the sealant on the collision reinforcement member.
  7. Knock the door panel loose and lift it away.
  8. Grind clean the door structure.
  9. Roughly cut the door panel so that it will overlap the joints on the door by 3 cm.
  10. Fit the new door panel on the door structure and fasten with a couple of welding clamps.
  11. Cut through the door panel and door structure outer plate at the same time to get a good fit, edge to edge. Work carefully and do not damage the door structure inner plate.
  12. Remove the door panel and grind clean any surfaces on the door panel and door structure that are to be welded.
  13. Apply welding primer to the surfaces that are to be spot welded. Use Teroson Zinkspray.
  14. Apply sealant between the collision reinforcement member and the door panel. Use Terostat 1K-PUR.
  15. Apply adhesive to the inside of the front, rear and bottom edges of the door panel. Use Teromix 6700.
    Fig 3: Illustration For Step 15
    G03509240Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Fit the door panel to the door structure and fix it with a few welding clamps. Tack-weld the door panel to the door frame.
    Fig 4: Illustration For Step 16
    G03509241Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Fold the front and rear edges of the door panel around the door structure. Start with a plastic mallet and a dolly and then continue with a hammer. Work in stages along each edge.
  18. Fit the door in place and check its fit and alignment with the body. Adjust as necessary.
  19. Completely weld the joints between the door panel and door frame.
    Fig 5: Illustration For Step 19
    G03509242Courtesy of SAAB-SCANIA OF AMERICA, INC.
  20. Grind all the welds.
  21. Spot-weld on the door panel.
    Fig 6: Illustration For Step 21
    G03509243Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Remove excess welding primer from the door. Welding primer makes for poorer adhesion of paint, body filler and sealant.
  23. Apply primer to all bare metal surfaces. Use Standox 1K Fullprimer.
  24. Use Terostat 1K-PUR to seal joints and metal folds.
  25. Fit a piece of sound insulating material to the inside of the door panel.
  26. Apply anti-corrosion agent to the door after it has been painted.
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