For 1990-2009 cars only
Removal Procedure
- Remove all related panels and components including the front door.
- Position all wiring out of the way to prevent damage.
- Visually inspect and restore as much of the damage as possible to factory specifications.
- Remove sealers and anti-corrosion materials as necessary.
- On the original outer door frame (2) measure down from the lower edge (1) of the door opening 200 mm (8 in) and mark a horizontal line.
- Cut the outer door frame along this line for sectioning.
- Locate, mark, and drill out all necessary factory welds. Note the number and location of welds for installation of the service section.
- Perform additional sectioning procedures as necessary to remove the center lock pillar.
- Remove the damaged section of the door frame opening (4).
Installation Procedure
- On the service part (4), mark a horizontal line to leave a gap of one and one-half times the thickness of the metal at the sectioning joint (5).
- Cut the service panel along this line.
- Drill 8 mm (5/16 in) holes for plug welding in the service part in the locations noted from the original panel (2).
- Drill holes for plug welding along the sectioning cuts on the service part.
- Locate these holes approximately 13 mm (½ in) from the edge of the sectioning cuts.
- Prepare the mating surfaces and position the service part using three-dimensional measuring equipment.
- Plug weld accordingly.
- Use the inner reinforcement (3) as a backing plate and stitch weld along the entire sectioning joint.
- Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
- Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
- Complete all other welds and sectioning procedures as necessary.
- Clean and prepare welded surfaces.
- Prime with two-part catalyzed primer.
- Apply sealers and anti-corrosion materials as necessary.
- Install all related panels and components.
Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturers recommendations.
