Installation

1. Center the new door insert on the door trim panel substrate.

2. Place the door trim panel assembly back on the cloth-type protective material with the heat-stake side up.

3. Place one hand on the front side of the door trim panel (the side that is on the work bench) at one of the door insert comers. Press and hold the door insert heat stake against the door trim panel substrate.

IMPORTANT:
A desirable round heat stake weld should have an approximate diameter of 10 mm (13/32 in.) and height 2 mm (3/32 in.).





4. Using a Weller(R) model 8200 soldering gun (or equivalent) equipped with a flat tip, use a circular motion around the heat stake. Apply firm steady pressure to spread the heat stake material onto the door trim panel substrate to achieve a proper weld.

5. After the heat stake has been melted, keep steady pressure with your hand on the door insert for 30 seconds, to allow the heat stake to harden.

6. Repeat Steps 3 through 5 for the remaining door insert comers.

7. Continue to press and hold the door insert against the door trim panel substrate and heat stake the remaining door insert studs.

8. Verify that the door insert is securely heat staked to the door trim panel substrate in all locations.





9. Install the door pull cup.

10. Install the door trim panel. (Refer to "Front Door Trim Panel" installation in the 2000/2001 Doors/Windows/Mirrors section of the Body/Electrical Volume I Service Manual.)