Removal Procedure
- Disable the SIR system. Refer to
SIR Disabling and Enabling
.
- Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Remove all related panels and components.
- Repair as much of the damage as possible to factory specifications. Refer to
Dimensions - Body
- Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair
.
- Remove the front outer hinge pillar. Refer to
Front Hinge Pillar Sectioning
.
- On the original reinforcement panel (1) measure 120 mm (4 in) down from the large wiring harness hole in the
hinge pillar and mark a horizontal line.
- Cut the inner reinforcement along this line.
- Locate, mark, and drill out all factory welds, as necessary. Note the number and location of welds for installation of the service part.
- Remove the damaged section of the inner reinforcement (2).
Installation Procedure
- Cut and remove 30 mm (1 3/16 in) from the flanges on either side of the remaining section of the original hinge
pillar to create a 30 mm (1 3/16 in) flange.
- Cut 5 mm (3/16 in) wide gaps in the bottom corners.
- Step the tabs inward to allow the door frame inner reinforcement service section to fit over the original
inner reinforcement.
- Weld the tabs together along the edges (1).
- On the service part (1) measure 90 mm (3 in) down from the large wiring harness hole in the hinge pillar and mark a horizontal line.
- Cut the hinge pillar reinforcement along this line.
- Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panel.
- Drill plug weld holes along the sectioning cut of the service part (2). These holes should be located approximately 15 mm (9/16 in) from the edge of the cut.
- Prepare mating surfaces.
- Apply GM approved Weld-Thru coating or equivalent to all mating surfaces. Refer to
Anti-Corrosion Treatment and Repair
.
- Position the service section (2) over the stepped tab on the original inner reinforcement (1) allowing 30 mm (1 3/16 in) of overlap.
- Inspect and verify that the door hinge bolt holes are properly located.
- Plug weld accordingly.
- Stitch weld along the entire joint with 25 mm (1 in) gaps between the welds.
- Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
- Install the front outer hinge panel. Refer to
Front Hinge Pillar Sectioning
.
- Clean and prepare all welded surfaces.
- Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to
Anti-Corrosion Treatment and Repair
.
- Paint the repair area. Refer to
Basecoat/Clearcoat Paint Systems
.
- Install all related panels and components.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
.
- Enable the SIR system. Refer to
SIR Disabling and Enabling
.