Important: When replacing panels that involve servicing stationary glass, refer to GM Service Bulletin No. 43-10-48 before performing any priming or refinishing.

1. Remove all related panels and components.
2. Visually inspect and restore as much of the damage as possible.
3. Remove sealers and anti-corrosion materials as necessary.



4. Cut the panel in the areas where the sectioning is to take place. Sectioning should be performed in recommended areas only.

Important: Use care not to cut the inner reinforcement when cutting the outer door frame.

5. Locate, mark and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
6. Remove the damaged outer door frame opening.

Important: When sectioning the outer door frame at the lower front hinge pillar or at the center lock pillar, the inner reinforcement panel can be used as a backing plate.

1. On service part, mark a horizontal line to leave a gap of one and one-half times the thickness of the metal at the sectioning joint (2).
2. Cut the outer door frame opening service part along this line.
3. Cut a 100 mm (94 in) piece from the unused portion of the service part for a backing plate (1).
4. Remove the flange on each side of the backing plate so that it will fit behind the sectioning joint.
5. Drill 8 mm (5/16 in) holes for plug welding in the service part in the locations noted from the original panel.
6. Drill holes for plug welding along the sectioning cuts on both the service part and the original panel.
7. Locate 3 holes approximately 25 mm (1 in) from the edge of the sectioning cuts.
8. Position the service part to overlap the exposed 50 mm (2 in) of the backing plate.
9. Check for proper fit. Use 3-dimensional measuring equipment.
10. Plug weld accordingly.
11. Stitch weld along the sectioning joint.
12. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
13. Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
14. Complete all other welds and sectioning procedures as necessary.
15. Clean and prepare welded surfaces.

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

16. Prime with 2-part catalyzed primer.
17. Apply sealers and anti-corrosion materials as necessary.
18. Install all related panels and components