GM Service Manual Online
For 1990-2009 cars only

Removal Procedure

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Caution: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause personal injury if the vehicle is in a collision.

Note the center pillar reinforcement must be removed from the vehicle to perform this operation.


    Object Number: 787781  Size: SH
  1. Remove all related panels and components.
  2. Disable the SIR system. Refer to SIR Disabling and Enabling .
  3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  4. Restore as much of the damage as possible.
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  6. Note structural adhesive locations.

  7. Object Number: 787782  Size: SH
  8. In the inner upper center pillar area, locate the "T" shaped opening on the inside of the pillar. Measure down (a) 100 mm (4 in) from the bottom of the opening. This is your sectioning location.

  9. Object Number: 787783  Size: SH
  10. In the inner rocker panel area, select the triangle shaped opening's in the front and rear of the pillar areas to be replaced as shown. These are your lower section locations.

  11. Object Number: 787785  Size: SH

    Important: Do not damage any inner reinforcements.

  12. Cut the panel where sectioning is to be performed.

  13. Object Number: 787786  Size: SH
  14. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.

  15. Object Number: 787788  Size: SH
  16. Remove the damaged center pillar.

Installation Procedure


    Object Number: 787789  Size: SH
  1. Cut the replacement service part in the pillar area (1) to allow for a (a) 25 mm (1 in) overlap of the original section cut.

  2. Object Number: 787791  Size: SH
  3. On the pillar area of the service part notch the weld flange areas as shown.

  4. Object Number: 787793  Size: SH
  5. Cut the service part in the corners as shown and step the tabs inward to allow the service part to fit under the original reinforcement.

  6. Object Number: 787794  Size: SH
  7. Cut the replacement service part vertically in the rocker panel areas to allow for a full overlap and notch as shown.
  8. Drill 8 mm (5/16 in) plug weld holes along the sectioning cut on the original reinforcement. Locate these holes 13 mm (½ in) from the edge and spaced 40 mm (1 ½ in) apart.

  9. Object Number: 787795  Size: SH
  10. Drill 8 mm (5/16 in) plug weld holes in the service reinforcement as necessary in the locations noted from the original panel.
  11. Prepare all mating surfaces as necessary.
  12. Apply 3M Weld-Thru Coating P/N 05913 or equivalent to all mating surfaces.

  13. Object Number: 787796  Size: SH
  14. Align the service part on the vehicle using 3-dimensional measuring equipment.

  15. Object Number: 787797  Size: SH
  16. Plug weld accordingly.
  17. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Go back and complete the stitch weld.
  18. Clean and prepare all of the welded surfaces.
  19. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  20. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  21. Install all of the related panels and components.
  22. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  23. Enable the SIR system. Refer to SIR Disabling and Enabling .