Side Door Opening Frame Replacement Outer A-Pillar

Removal Procedure

Important: The full body-side outer panel comes as a one-piece assembly and can be replaced at factory seams after removal of glass. Any one of these prodedures 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. Left and right service parts are structurally identical but have varied service slot placement in mid rocker areas. Remove front and rear glass when sectioning A-pillar and quarter panel. Refer to Windshield Replacement and Rear Window Replacement .

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove the fender.
3. Remove the windshield.
4. Remove the door.



5. Drill out factory the spot welds of the upper-outer rail.
6. Remove the upper rail and save for reinstallation.



7. Determine sectioning locations. Section in specified areas only.
8. Mark locations and cut part through outer panel only.
9. Note the number and location of the factory welds and drill them out.
10. Remove the outer panel.




Important: Hinge pillar blocks must be replaced if damaged.

11. Note the placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available.

Installation Procedure

1. Cut the 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 a 100 mm (4 in) backing plate on the rocker panel from the unused portion of the service part.
3. In windshield pillar area, create 50 mm (2 in) backing plate fro unused portion of service part. Remove flange from backing plates for proper fit behind sectioning joint.
4. Drill 8 mm (5/16 in) plug weld holes in service part according to original locations as noted, and in original panel where parts overlap backing plate.
5. Prepare all mating surfaces as necessary.
6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
7. Weld backing plates to vehicle.

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

8. Position service part on the vehicle.
9. Clamp the part in place and check for proper fit.
10. Plug weld accordingly.



11. Stitch weld along the entire sectioning joint. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
12. Complete the stitch weld in order to ensure the structural integrity of the vehicle.
13. Install upper rail assembly.
14. Grind welds as necessary along seams.
15. Finish surface as necessary.
16. Install insulating foam as necessary in areas noted from original baffle locations.

Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

17. Refinish as necessary.

Side Door Opening Frame Replacement Inner A-Pillar

Removal Procedure

The full body-side inner panel comes as a one-piece assembly and can be replaced at factory seams after removal of outer panel, roof and glass. Any one of these procedures can be performed separately, or in any combination, dependent upon the extent of damage to the vehicle. Remove the front and rear glass when sectioning the A-pillar and the quarter panel. Refer to Windshield Replacement and Rear Window Replacement .

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

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove the outer panel according to the specified directions in the removal process.
3. Remove the following:

•	The dashboard

•	The instrument panel

•

The seat

•	All the necessary components to allow access to repair




4. Locate and follow the laser-weld line (1) across the A-pillar at lower windshield area.
5. Measure down 50 mm (2 in) and scribe a line parallel to the laser-weld line (2). This is your cut location.
6. Cut damaged part at cut location.
7. At rocker panel, locate sectioning location (3).
8. Scribe a line.

Important: Left and right service parts are structurally identical but have varied service slot placement in mid-rocker areas. On the right side rocker, section at rear of access hole on original panel. Overlap service part 50 mm (2 in) and use access holes as alignment guides.

9. Cut through one layer of metal only at the cut location.
10. Drill out the factory spot welds.
11. Remove the damaged panel.

Create Service Flange

1. On windshiled pillar lower edge, measure forward 25 mm (1 in) (1) from door opening.
2. Scribe a vertical line.
3. Measure forward 190 mm (7 ½ in) from first scribed line and scribe a second vertical line (2).
4. Cut along vertical markings to laser-weld line (1), to create a flange for welding service part.
5. Cut along laser-weld, outboard of vertical cuts, and remove tabs. This creates a 50 mm (2 in) x 190 mm (10 7/8 in) tab (2) for attaching service part to A-pillar.

Preparation of Service Part

1. Locate laser-weld at bottom of windshield pillar area of the service part. This will be the same laser-weld location as the on the original panel (1).
2. Cut along laser-weld (1).
3. Create a vertical line for sectioning rocker (3). Allow space for a 50 mm (2 in) overlap for welding.
4. Notch upper and lower edges of service part to fit behind existing rocker panel, and remove tabs.
5. Drill plug weld holes in locations noted from original panel.

Installation Procedure

1. Drill plug weld holes in A-pillar flange, spaced 38 mm (1 ½ in) apart (2).
2. Drill plug weld holes at rocker overlap.
3. Prepare all mating surfaces as necessary.
4. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

5. Prime with 2-part catalyzed primer.
6. Position part on vehicle and clamp in place. Check fit.
7. Plug weld accordingly.
8. Stitch weld at A-pillar (1), at rocker-inner (3), and at sectioning locations.
9. Weld and grind the seams.
10. Refinish as necessary.
11. Install all related panels and components.

Side Door Opening Frame Replacement Outer B-Pillar

Removal Procedure

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

1. Measure down 130 mm (5 1/8 in) from the top edge of the B-pillar top crease.
2. Mark and scribe a line. This is the cut location.



3. Cut B-pillar at cut line. Use care to not cut inner reinforcement. The inner reinforcement will be used for a backing plate (1).



4. Create cut lines on rocker within approved sectioning locations. Cut the rocker vertically along the sectioning lines.
5. Drill out the factory welds.

Important: The B-pillar is bonded and welded above hinges.

6. Use care to not damage inner reinforcement when removing outer panel.
7. Remove damaged part.
8. Note placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available.

Service Part Preparation

1. On the service part, mark a horizontal line in corresponding locations to the original sectioning cut, to leave a gap of one and one half times the thickness of the metal at the sectioning joint.
2. Cut the outer door frame opening service part along this line.
3. Make vertical cut lines in rocker areas to correspond with original section lines. Leave a gap one and one half times the metal thickness.
4. Cut two 100 mm (4 in) pieces from the unused portion of the service part for backing plates.



5. 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.
8. Apply weld-through primer to mating surfaces prior to assembly.
9. Install foam baffles as necessary.

Installation Procedure

1. Install sleeves on vehicle at rocker area. inner reinforcement will be used as a backing plate on B-pillar.
2. Prepare all mating surfaces as necessary.
3. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
4. Position part on vehicle.
5. Clamp in place and check for proper fit.
6. Remove service part and apply urethane to B-pillar reinforcement (1) in areas corresponding to original locations.
7. Replace hinge blocks.
8. Align part and clamp in place and check fit.
9. Plug weld as necessary.
10. Stitch weld one inch on and one inch off as necessary.
11. Prepare mating surfaces.

Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

12. Grind and finish seams as necessary.
13. Prime with 2-part catalyzed primer. Refinish as necessary.

Side Door Opening Frame Replacement Inner B-Pillar

Removal Procedure

1. Remove the following:

•

The seats

•	The carpet

•	All related panels and components

2. Secure wiring from repair area.
3. Remove inner reinforcement (1) by drilling approximately 8 spot welds.
4. Measure down 135 mm (5 5/8 in) from upper-inner reinforcement. Scribe a horizontal cut line.
5. At front door rocker area, scribe a vertical cut line at the rear edge of the 50 mm x 100 mm (2 in x 4 in) oval hole (3).
6. Cut on the 3 scribed lines.
7. Drill out factory spot welds, noting their location for installation of service part.
8. Remove the damaged panel.

Preparation of Service Part

1. Remove inner reinforcement (1) on B-pillar.
2. Cut service part at top of 24 mm round hole (1) located midway down the B-pillar.
3. Cut down 40 mm (1 5/8 in) of the outturned weather-strip flanges on the B-pillar (2).
4. Trim inside corners for flush fit.
5. At front door rocker area, cut service part, allowing for a 50 mm (2 in) overlap to original cut line on inner rocker.
6. Trim a 20 mm x 50 mm (13/16 in x 2 in) tab at top and bottom (1) of sectioned area on service part to allow for a flush fit at pinch welds.
7. In the rear door, inner rocker area, trim tabs and use the front edge of the next 50 mm x 100 mm (2 in x 4 in) oval hole as an alignment guide to create a 50 mm (2 in) overlap.
8. Drill plug weld holes in sectioning areas, 25 mm (13/16 in) back from cut line on rocker pillar area.
9. Drill 8 mm (5/16 in) plug weld holes as noted from original locations.
10. Prepare all mating surfaces as necessary.
11. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

Installation Procedure

Important: Prior to refinishing, refer to publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

1. Apply 2-part catalyzed primer to B-pillar area and service part.
2. Clamp part in position. Check for fit.
3. Spot-blast plug weld areas.
4. Plug weld as necessary.
5. Complete stitch welds at section areas.
6. Grind and finish seams as necessary.
7. Install upper reinforcement.
8. Refinish as necessary.
9. Install all related panels and components.