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Home >> Saab >> 2005 >> 9-5 Linear, Automatic >> Repair and Diagnosis (Single Page) >> Accessories & Equipment >> Anti-Theft Systems >> Doors & Locks - 9-5 >> Adjustment - Replacement >> Front door, outer door panel >> To fit

To fit

Fig 1: Illustration For Step 6
G03865896Courtesy of SAAB-SCANIA OF AMERICA, INC.
  1. Position the new door panel and mark where to cut.
  2. Cut the door panel to the markings
  3. Grind clean the surfaces on the door panel that are to be welded.
  4. Apply welding primer to the surfaces that are to be spot welded. Use Teroson Zinkspray.
  5. Apply sealant between the collision reinforcement member and the door panel. Use Terostat 1K-PUR.
  6. Apply adhesive to the inside of the front, rear and bottom edges of the door panel. Use Teomix 6700.
  7. Fit the door panel to the door structure and fix it with a couple of welding clamps. Tack-weld the door panel to the door frame.
    Fig 2: Illustration For Step 7
    G03865897Courtesy of SAAB-SCANIA OF AMERICA, INC.
  8. 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.
  9. Fit the door in place and check its alignment with the body. Adjust as necessary.
  10. All-weld the joints between the door panel and door frame.
    Fig 3: Illustration For Step 10,12
    G03865898Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. Smooth off the welds.
  12. Spot-weld on the door panel.
    NOTE: Do not forget the welds on the inside (door seam).
  13. Wash off surplus welding primer. Welding primer makes for poorer adhesion of paint, filler and sealant.
  14. Apply primer to all bare metal surfaces. Use Standox 1K Full primer.
  15. Use Terostat 1K-PUR to seal joints and metal folds.
  16. Fit a batt of insulating material to the inside of the door panel.
  17. Apply anti-corrosion agent to the door after it has been painted.
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