Side Door Opening Frame Replacement Outer A-Pillar

The full body-side outer panel comes as a one-piece assembly and can be replaced at factory seams after removal of glass and roof. Any one of these procedures can be performed separately, or in any combination, dependent upon the extent of damage to the vehicle. Sectioning must take place in specified areas only. Remove front glass when sectioning A-pillar and rear glass for quarter panel repair.

Important: When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin 43-10-48 before performing any priming or refinishing.

Outer A-Pillar

1. Visually inspect and restore as much of the damage as possible to the factory specifications.
2. Remove the following:

•

fender

•

door

•	upper rail

•	windshield

3. Determine sectioning locations. Section in approved areas only.
4. Mark locations and cut in approved sectioning areas. Cut through outer panel only.
5. Locate factory welds and drill out, noting the number and the locations of welds.



6. Locate and drill out spot welds on weatherstrip retainer as necessary to service part. It is not necessary to remove complete retainer.

•	Remove all foam prior to welding this section of service panel.

•	Hinge pillar blocks must be replaced if damaged.

7. Note placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available.
8. Remove outer panel.
9. Clean adhesive and sealer from hydroformed reinforcement tube as necessary. Note location for reinstallation.

1. Cut service part in corresponding locations to fit original cut lines. Leave a gap of one-and-one-half times the metal thickness of sectioning joint.
2. Create 100 mm (4 in) backing plate on rocker panel from unused portion of the service part.
3. In windshield pillar area, use the hydroformed inner rail for backing plate.
4. Drill 8 mm (5/16 in) plug weld holes in the service part according to original locations as noted, and in original panel where backing plate overlaps.
5. Apply weld-through primer to mating surfaces prior to assembly.
6. Weld backing plates to vehicle at rocker.

Important: Replace hinge pillar blocks prior to welding outer panel.

7. Apply windshield bonding adhesive to the hydroformed reinforcement as noted from removal procedure.
8. Position service part on vehicle.
9. Clamp in place and check for proper fit.
10. Plug weld accordingly, stitch weld along the entire sectioning mount. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
11. Go back and complete the stitch weld to ensure structural integrity of the vehicle.
12. Dress welds as necessary along seams. Finish surface as necessary.
13. Install insulating foam as necessary in areas noted from original baffle locations.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

14. Prepare mating surfaces.
15. Refinish as necessary.
16. Install all related panels and components.

Side Door Opening Frame Replacement Outer B-Pillar

Important: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle.

1. Locate an approved sectioning area in the B-Pillar.



2. Mark and scribe a line. This is the cut location.
3. Cut B-Pillar at cut line. Use caution to not cut inner reinforcement.
4. Create cut lines on rocker within approved sectioning locations. Cut the rocker vertically along cut lines.
5. Drill out factory welds. Note the number and location of the welds.
6. Note placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available.
7. Remove the damaged part.

1. On the service part, at B-Pillar, mark a horizontal line in corresponding locations to original sectioning cut. Leave a gap of one-and-one-half times the metal thickness (1).
2. Mark vertical cut lines in rocker areas to correspond with original section lines. Leave a gap of one-and-one-half times the metal thickness (1).
3. Cut the outer door frame opening service part along these three section lines.
4. Cut two 100 mm (4 in) pieces from the unused portion of the service part for backing plates in rocker.
5. Cut one 50 mm (2 in) backing plate for pillar. Remove the flange on each side of the backing plates so that they will fit behind the sectioning joint.
6. Drill 8 mm (5/16 in) holes for plug welding in the service part in the locations noted from the original panel.
7. Drill holes for plug welding along the sectioning cuts on both the service part and the original panel. Locate these holes approximately 25 mm (1 in) from the edge of the sectioning cuts.

1. Install sleeves on vehicle at rocker and B-Pillar areas using plug welds.
2. Replace hinge blocks and bolts.
3. Prepare mating surfaces.

Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

4. Apply weld-through primer to mating surfaces prior to assembly.
5. Align part and clamp in place. Check fit.
6. Spot blast plug weld areas.
7. Plug weld as necessary in original spot weld locations and at backing plates.
8. Stitch weld at section joints, one inch on and one inch off, as necessary.
9. Go back and complete the stitch weld. This will create a solid joint with minimum heat distortion.
10. Dress welds and finish seams as necessary.
11. Refinish as necessary.