Side Door Opening Frame Replacement Sportwagon

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

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the engine assembly. Refer to Engine Replacement for the 3.6L Engine or Engine Replacement for the 6.0L Engine.
4. Remove the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
5. Remove the brake master cylinder. Refer to Master Cylinder Replacement.
6. Remove the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement.
7. Remove the engine control module. Refer to Engine Control Module Replacement for the 3.6L Engine or Engine Control Module Replacement for the 6.0L Engine.
8. Remove the underhood electrical centre. Refer to Underhood Electrical Center or Junction Block Replacement.
9. Remove the negative battery cable. Refer to Battery Negative Cable Replacement.
10. Remove the positive battery cable from the engine bay. Refer to Battery Positive Cable Replacement.
11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
12. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
13. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
14. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
15. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
16. Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
17. Remove the front fender assembly. Refer to Front Fender Replacement.
18. Remove the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
19. Remove the front strut assembly. Refer to Strut Assembly Replacement.
20. Remove the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
21. Remove the rear frame assembly. Refer to Rear Frame Replacement.

Important: This step is unique to the right side body ring.

22. Remove the filler tube. Refer to Filler Tube Replacement for the 3.6L Engine or Filler Tube Replacement for the 6.0L Engine.

Important: This step is unique to the right side body ring.

23. Remove the fuel filler door. Refer to Fuel Tank Filler Door Replacement.

Important: This step is unique to the right side body ring.

24. Remove the fuel filler door release actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.
25. Remove the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis for the 3.6L Engine or Fuel Hose/Pipes Replacement - Chassis for the 6.0L Engine.
26. Remove the fuel tank. Refer to Fuel Tank Replacement for the 3.6L Engine or Fuel Tank Replacement for the 6.0L Engine.
27. Remove the brake lines. Refer to Brake Pipe Replacement.
28. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
29. Remove the plenum chamber. Refer to Air Inlet Assembly Replacement.
30. Remove the front doors. Refer to Front Side Door Replacement.
31. Remove the rear doors. Refer to Rear Door Replacement.
32. Remove the front seats. Refer to Front Seat Replacement - Bucket.
33. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
34. Remove the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
35. Remove the front seat belts. Refer to Front Seat Belt Replacement.
36. Remove the rear seat belts. Refer to Rear Seat Belt Replacement.
37. Remove the instrument panel carrier. Refer to Instrument Panel Carrier Replacement.
38. Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement.
39. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
40. Remove the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
41. Remove the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
42. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
43. Remove the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
44. Remove the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
45. Remove the headliner. Refer to Headlining Trim Panel Replacement.
46. Remove the body side stationary window. Refer to Body Side Window Replacement.
47. Remove the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement.
48. Remove the positive battery cable from the vehicle. Refer to Battery Positive Cable Replacement.
49. Remove roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
50. Remove the rocker panel moulding. Refer to Rocker Panel Molding Replacement.
51. Remove the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
52. Remove the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
53. Remove the liftgate. Refer to Liftgate Replacement.
54. Remove the rear header panel. Refer to Customer Concern Verification Sheets.
55. Note the location and remove sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



56. Remove the body side panel to upper dash panel body sealer (1).



57. Locate, mark and drill out the factory welds attaching the upper wheel house brace to the front wheelhouse assembly (1).



58. Locate, mark and drill out the factory welds attaching the upper wheelhouse brace to the front hinge pillar (1).



59. Locate, mark and remove the factory seam welds attaching the body side panel assembly to the front hinge pillar (1).
60. Remove the upper wheelhouse brace from the front wheelhouse assembly.



61. Locate, mark and drill out the factory welds attaching the upper wheelhouse brace to the front hinge pillar (1).



62. Locate, mark and drill out the factory welds attaching the body side panel assembly to the front hinge pillar (1).



63. Locate, mark and drill out the factory welds attaching the body side panel assembly to the vehicle (1).



64. Locate, mark and remove the factory welds attaching the body side panel assembly to the vehicle (1).
65. Remove the Roof Rear Header Panel. Refer to Roof Rear Header Panel Replacement.
66. Remove the Roof Front Header Panel. Refer to Roof Front Header Panel Replacement.
67. Remove the Front Roof Panel Bow. Refer to Roof Panel Bow Replacement.
68. Remove the Rear Roof Panel Bow. Refer to Roof Panel Bow Replacement.



69. Locate, mark and remove the factor seam welds (1) attaching the body side panel assembly to the inner rocker panel.



70. Locate, mark and remove the factory seam welds (1) attaching the body side panel assembly to the rear inner wheelhouse.



71. Locate, Mark and drill out the factory welds (1) attaching the body side panel assembly to the vehicle.



72. Locate, mark and drill out the factory welds (1) attaching the body side panel assembly to the rear floor panels.



73. Locate, mark and drill out the factory welds (1) attaching the body side panel assembly to the rear floor panels.



74. Locate, mark and drill out the factory welds (1) attaching the body side panel assembly to the rear floor panels.



75. Locate, mark and drill out the factory welds (1) attaching the body side panel assembly to the rear floor panels.



76. Locate, mark and drill out the factory welds (1) attaching the body side panel to the back body pillar inner lower panel.



77. Locate, mark and drill out the factory welds (1) attaching the body side panel assembly to the rear wheelhouse inner panel front reinforcement.
78. Remove the body side panel assembly from the vehicle.




Important: Clean all adhesive mating surfaces in accordance with the adhesive manufacturer's specifications.

79. Remove the sealer (1) from the front plenum panel.
80. Remove the seam sealer (2) from the body side.




Important: Clean all adhesive mating surfaces in accordance with the adhesive manufacturer's specifications.

81. Remove the sealer (1) from the rear edge of the upper wheelhouse brace.




Important: Clean all adhesive mating surfaces in accordance with the adhesive manufacturer's specifications.

82. Remove the sealer (1) from the rear floor pan assembly.




Important: Clean all adhesive mating surfaces in accordance with the adhesive manufacturer's specifications.

83. Remove the sealer (1) from the inner quarter panel.




Important: Clean all adhesive mating surfaces in accordance with the adhesive manufacturer's specifications.

84. Remove the sealer (1) from the top edge of the inner hinge pillar.

Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

Important: Ensure that all factory welds are replaced in their original locations.

Important: Ensure that all structural adhesives and sealers are replaced in their original locations.

Important: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when disassembling.
2. Clean and prepare the mating surfaces of both parts of the body side panel assembly.

Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that were originally covered by secondary sealer.




3. Install the un-expanded noise baffle (1) to the body side panel assembly.



4. Apply the primary sealer to the top edge of the inner hinge pillar (1).



5. Apply the secondary sealer along the rear floor pan assembly (1).



6. Apply the primary sealer (1) between the inner rocker panel and the inner quarter panel.



7. Apply the primary sealer along the rear edge of the upper wheelhouse brace (1).



8. Apply the primary sealer along the lower hinge pillar (1).



9. Align the body side panel assembly by positioning the rear wheelhouse inner panel front reinforcement flange (1) up against the inner rocker panel flange (3).
10. Align the body side panel assembly by positioning the rib in the rear wheelhouse inner panel front reinforcement (1) with the corresponding rib (2) in the rear wheelhouse inner panel.



11. Align the body side panel assembly by positioning the inner wheelhouse panel (1) up against the rear floor panel (2).



12. Align the body side panel assembly centre pillar to the indented flange on the inner rocker panel (1).



13. Align the body side panel hinge pillar (1) to the inner lower hinge pillar (2).



14. Weld the body side panel assembly to the front hinge pillar (1).



15. Seam weld the inner lower hinge pillar to inner upper hinge pillar (1) 60 mm (2.36 in) using a metal inert gas (MIG) welder.



16. Weld the body side panel assembly to the front hinge pillar (1).



17. Weld the body side panel assembly to the rear floor panels (1).



18. Weld the body side panel to the back body pillar inner lower panel (1).



19. Weld the body side panel assembly to the rear wheelhouse inner panel front reinforcement (1).



20. Weld the body side panel assembly to the rear floor panels (1).



21. Weld the body side panel assembly to the rear floor panels (1).



22. Weld the body side panel assembly to the rear floor panels (1).



23. Weld the body side panel assembly to the vehicle (1).



24. Seam weld the body side panel assembly to the rear inner wheelhouse (1).



25. Seam weld the body side panel assembly to the inner rocker panel (1).
26. Install the Roof Rear Header Panel. Refer to Roof Rear Header Panel Replacement.
27. Install the Roof Front Header Panel. Refer to Roof Front Header Panel Replacement.
28. Install the Front Roof Panel Bow. Refer to Roof Panel Bow Replacement.
29. Install the Rear Roof Panel Bow. Refer to Roof Panel Bow Replacement.



30. Weld the upper wheelhouse brace to the front hinge pillar (1).



31. Position the upper wheelhouse brace to the front wheelhouse assembly.
32. Seam weld the body side panel assembly to the front hinge pillar (1).



33. Weld the upper wheelhouse brace to the front hinge pillar (1).



34. Weld the upper wheel house brace to the front wheelhouse assembly (1).

Important: All joints and welds must be checked for water leaks before the vehicle is fully reassembled.

35. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
36. Install the roof outer panel. Refer to Roof Outer Replacement.
37. Install the liftgate. Refer to Liftgate Replacement.
38. Install the body side roof drip moulding. Refer to Body Side Roof Drip Molding Replacement.
39. Install the windshield pillar garnish moulding. Refer to Windshield Pillar Garnish Molding Replacement.
40. Install the rocker panel moulding. Refer to Rocker Panel Molding Replacement.
41. Install the roof weld joint reveal moulding. Refer to Roof Weld Joint Reveal Molding Replacement.
42. Install the positive battery cable from the vehicle. Refer to Battery Positive Cable Replacement.
43. Install the remote function actuator. Refer to Remote Control Door Lock Receiver and Theft Deterrent Module Replacement.
44. Install the body side stationary window. Refer to Body Side Window Replacement.
45. Install the headliner. Refer to Headlining Trim Panel Replacement.
46. Install the body side window rear garnish moulding. Refer to Body Side Window Rear Garnish Molding Replacement.
47. Install the headlining rear trim panel retainer. Refer to Headlining Rear Trim Panel Retainer Replacement.
48. Install the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement.
49. Install the load floor front panel carpet. Refer to Load Floor Front Panel Carpet Replacement.
50. Install the load floor stationary panel carpet. Refer to Load Floor Stationary Panel Carpet Replacement.
51. Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
52. Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement.
53. Install the Instrument panel carrier. Refer to Instrument Panel Carrier Replacement.
54. Install the rear seat belts. Refer to Rear Seat Belt Replacement.
55. Install the front seat belts. Refer to Front Seat Belt Replacement.
56. Install the rear seat back. Refer to Rear Split Folding Seat Back Replacement.
57. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
58. Install the front seats. Refer to Front Seat Replacement - Bucket.
59. Install the rear doors. Refer to Rear Door Replacement.
60. Install the front doors. Refer to Front Side Door Replacement.
61. Install the plenum chamber. Refer to Air Inlet Assembly Replacement.
62. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
63. Install the brake lines. Refer to Brake Pipe Replacement.
64. Install the fuel tank. Refer to Fuel Tank Replacement for the 3.6L Engine or Fuel Tank Replacement for the 6.0L Engine.
65. Install the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis for the 3.6L Engine or Fuel Hose/Pipes Replacement - Chassis for the 6.0L Engine.

Important: This step is unique to the right side body ring.

66. Install the fuel filler door release actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right side body ring.

67. Install the fuel filler door. Refer to Fuel Tank Filler Door Replacement.

Important: This step is unique to the right side body ring.

68. Install the filler tube. Refer to Filler Tube Replacement for the 3.6L Engine or Filler Tube Replacement for the 6.0L Engine.
69. Install the rear frame assembly. Refer to Rear Frame Replacement.
70. Install the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
71. Install the front strut assembly. Refer to Strut Assembly Replacement.
72. Install the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
73. Install the front fender assembly. Refer to Front Fender Replacement.
74. Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
75. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.
76. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
77. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
78. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
79. Install the positive battery cable from the engine bay. Refer to Battery Positive Cable Replacement.
80. Install the negative battery cable. Refer to Battery Negative Cable Replacement.
81. Install the underhood electrical centre. Refer to Underhood Electrical Center or Junction Block Replacement.
82. Install the engine control module. Refer to Engine Control Module Replacement for the 3.6L Engine or Engine Control Module Replacement for the 6.0L Engine.
83. Install the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement.
84. Install the brake master cylinder. Refer to Master Cylinder Replacement.
85. Install the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
86. Install the engine assembly. Refer to Engine Replacement for the 3.6L Engine or Engine Replacement for the 6.0L Engine.
87. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
88. Enable the SIR system. Refer to SIR Disabling and Enabling.
89. If reprogramming is required. Refer to Control Module References.

Side Door Opening Frame Replacement LWB

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

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the front doors. Refer to Front Side Door Replacement.
4. Remove the rear doors. Refer to Rear Door Replacement.
5. Remove the engine assembly. Refer to Engine Replacement or Engine Replacement.
6. Remove the negative cable from the engine bay. Refer to Battery Negative Cable Replacement.
7. Remove the positive cable from the engine bay. Refer to Battery Positive Cable Replacement.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Important: This step is unique to the right body side ring.

9. Remove the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.

Important: This step is unique to the right body side ring.

10. Remove the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

11. Remove the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.
12. Remove the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.
13. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
14. Remove the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
15. Remove the rear frame assembly. Refer to Rear Frame Replacement.
16. Remove the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.
17. Remove the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
18. Remove the front strut assembly. Refer to Strut Assembly Replacement.
19. Lower the vehicle.
20. Remove the brake lines. Refer to Brake Pipe Replacement.
21. Remove the fender assembly. Refer to Front Fender Replacement.
22. Remove the front fascia. Refer to Front Bumper Fascia Replacement.
23. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement.
24. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
25. Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
26. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
27. Remove the plenum chamber. Refer to Air Inlet Assembly Replacement.
28. Remove the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
29. Remove the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
30. Remove the brake master cylinder. Refer to Master Cylinder Replacement.
31. Remove the instrument panel. Refer to Instrument Panel Carrier Replacement.
32. Remove the HVAC. Refer to HVAC Module Assembly Replacement.
33. Remove the front seats. Refer to Front Seat Replacement - Bucket.
34. Remove the rear seat back. Refer to Rear Seat Back Replacement.
35. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
36. Remove the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
37. Remove the front seat belts. Refer to Front Seat Belt Replacement.
38. Remove the rear seat belts. Refer to Rear Seat Belt Replacement.
39. Remove the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
40. Remove the spare wheel and emergency kit from the rear compartment.
41. Remove the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
42. Remove the battery tray. Refer to Battery Tray Replacement.
43. Remove the positive cable from the vehicle. Refer to Battery Positive Cable Replacement.

Important: This step is unique to the sunroof.

44. Remove the sunroof module. Refer to Sunroof Module Assembly Replacement.
45. Remove the roof. Refer to Roof Outer Replacement.
46. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



47. Remove the body side ring to upper dash panel body sealer (1)



48. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front wheelhouse assembly.
49. Remove the upper wheelhouse brace from the front wheelhouse assembly.



50. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



51. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



52. Locate, mark and drill out the factory welds (1) attaching the body side ring to the front hinge pillar.



53. Locate, mark and remove the factory seam welds (1) attaching the body side ring centre pillar to the inner rocker panel.



54. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the rear inner wheelhouse.



55. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the front hinge pillar.



56. Locate, mark and drill out the factory welds (1) attaching the body side ring to the vehicle.



57. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the parcel shelf assembly.



58. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the upper parcel shelf assembly.



59. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



60. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



61. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the rear end panel.
62. Remove the body side ring from the vehicle.



63. Remove the sealer (1) from the front plenum panel.
64. Remove the seam sealer (2) from the lower hinge pillar.



65. Remove the seam sealer (1) from the rear floor pan assembly.



66. Remove the seam sealer (1) from the inner side extension panel.



67. Remove the seam sealer (1) from the rear end panel.

Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Spot welding is the preferred method for attaching panels and should be used wherever possible. A plug weld should be performed where your spot welder is unable reach.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
2. Clean and prepare the mating surfaces of both parts of the body side ring.



3. Remove the unexpanded noise baffle (1) from the body side ring.



4. Apply structural adhesive (1) GM6449G or equivalent 260 mm (10.24 in) (A) to the top edge of the inner hinge pillar.
5. Apply structural adhesive (1) GM6449G or equivalent 400 mm (15.75 in) (B) to the inner rocker panel.



6. Apply structural adhesive (1) GM6449G or equivalent 50 mm (1.97 in) (A) to the rear seat back on the forward facing surface.



7. Apply structural adhesive (1) GM6449G or equivalent 110 mm (4.33 in) (A) to the parcel shelf.



8. Apply structural adhesive (1) GM6449G or equivalent 40 mm (1.57 in) (A) to the body side centre roof bow.
9. Apply structural adhesive (1) GM6449G or equivalent 60 mm (2.36  (B) to the body side front roof bow.



10. Apply the primary sealer (1) GM6449G or equivalent along the lower hinge pillar.



11. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the parcel shelf panel.
12. Position the body side on the vehicle. Verify correct alignment and position using three-dimensional measuring equipment.



13. Align the body side ring to the inner rocker flange tab (1).



14. Align the inner rear wheelhouse (1) to side extension panel (2).



15. Align the body side ring centre pillar to the indented flange (1) on the inner rocker panel.



16. Align the body side ring hinge pillar (2) to the wheelhouse assembly.
17. Align the body side ring hinge pillar (1) to the inner lower hinge pillar.



18. Seam weld the inner lower hinge pillar to inner upper hinge pillar 60 mm (2.36 in) (A) using a (Metal Inert Gas) MIG welder.



19. Seam weld the inner quarter panel to rear floor assembly 60 mm (2.36 in) (A) across the locating tag using a MIG welder.



20. Seam weld the centre pillar to inner rocker panel in two places 50 mm (1.97 in) (A) across the locating tags using a MIG welder.
21. Install the roof. Refer to Roof Outer Replacement.



22. Weld (1) the body side ring to the vehicle.



23. Weld (1) the body side ring to the front hinge pillar.



24. Weld (1) the body side ring assembly to the inner rear side extension panel.



25. Weld (1) the body side ring assembly to the inner rear wheelhouse.



26. Weld (1) the body side ring assembly to the rear end panel.



27. Weld (1) the body side ring assembly to the upper parcel shelf assembly.



28. Weld (1) the body side ring assembly to the parcel shelf assembly.



29. Weld (1) the upper wheelhouse brace to the front hinge pillar.



30. Weld (1) the upper wheelhouse brace to the front hinge pillar.



31. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the upper wheelhouse brace.



32. Weld (1) the upper wheelhouse brace to the front wheelhouse assembly.



33. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the tail lamp and the quarter panel extension.



34. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the rear edge of the parcel shelf panel.



35. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the quarter panel extension.



36. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the front plenum panel.
37. Apply the secondary sealer (2) GM specification 9984532 or equivalent to the lower hinge pillar.



38. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the inner rear wheelhouse assembly.



39. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



40. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



41. Apply expanding foam sealer GM9982296 or equivalent to the front lower hinge pillar through the access hole (1).



42. Apply expanding foam sealer GM9982296 or equivalent through the two access holes (1) in the rear wheelhouse assembly.




Important: This step is unique to the right body side ring.

43. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the fuel filler pocket.
44. Install the positive cable to the vehicle. Refer to Battery Positive Cable Replacement
45. Install the battery tray. Refer to Battery Tray Replacement.
46. Install the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
47. Install the spare wheel and emergency kit from the rear compartment.
48. Install the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
49. Install the rear seat belts. Refer to Rear Seat Belt Replacement.
50. Install the front seat belts. Refer to Front Seat Belt Replacement.
51. Install the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
52. Install the rear seat back. Refer to Rear Seat Belt Replacement.
53. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
54. Install the front seats. Refer to Front Seat Replacement - Bucket.
55. Install the HVAC. Refer to HVAC Module Assembly Replacement.
56. Install the instrument panel. Refer to Instrument Panel Carrier Replacement.
57. Install the brake master cylinder. Refer to Master Cylinder Replacement.
58. Install the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
59. Install the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
60. Install the plenum chamber. Refer to Air Inlet Assembly Replacement.
61. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
62. Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
63. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
64. Install the fender assembly. Refer to Front Fender Replacement.
65. Install the front fascia. Refer to Front Bumper Fascia Replacement.
66. Install the rear fascia. Refer to Rear Bumper Fascia Replacement.
67. Install the brake lines. Refer to Brake Pipe Replacement.
68. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
69. Install the front strut assembly. Refer to Strut Assembly Replacement
70. Install the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
71. Install the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.

Important: This step is unique to the right body side ring.

72. Install the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.

Important: This step is unique to the right body side ring.

73. Install the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

74. Install the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

75. Install the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.
76. Install the rear frame assembly. Refer to Rear Frame Replacement.
77. Install the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
78. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
79. Lower the vehicle.
80. Install the front doors. Refer to Front Side Door Replacement.
81. Install the rear doors. Refer to Rear Door Replacement.
82. Install the positive cable to the engine bay. Refer to Battery Positive Cable Replacement.
83. Install the negative cable to the engine bay. Refer to Battery Negative Cable Replacement.
84. Install the engine assembly. Refer to Engine Replacement or Engine Replacement.
85. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
86. Enable the SIR system. Refer to SIR Disabling and Enabling.

Side Door Opening Frame Replacement SWB

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

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the front doors. Refer to Front Side Door Replacement.
4. Remove the rear doors. Refer to Rear Door Replacement.
5. Remove the engine assembly. Refer to Engine Replacement or Engine Replacement.
6. Remove the negative cable from the engine bay. Refer to Battery Negative Cable Replacement.
7. Remove the positive cable from the engine bay. Refer to Battery Positive Cable Replacement.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Important: This step is unique to the right body side ring.

9. Remove the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.

Important: This step is unique to the right body side ring.

10. Remove the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

11. Remove the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.
12. Remove the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.
13. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
14. Remove the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
15. Remove the rear frame assembly. Refer to Rear Frame Replacement.
16. Remove the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.
17. Remove the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
18. Remove the front strut assembly. Refer to Strut Assembly Replacement.
19. Lower the vehicle.
20. Remove the brake lines. Refer to Brake Pipe Replacement.
21. Remove the fender assembly. Refer to Front Fender Replacement.
22. Remove the front fascia. Refer to Front Bumper Fascia Replacement.
23. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement.
24. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
25. Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
26. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
27. Remove the plenum chamber. Refer to Air Inlet Assembly Replacement.
28. Remove the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
29. Remove the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
30. Remove the brake master cylinder. Refer to Master Cylinder Replacement.
31. Remove the instrument panel. Refer to Instrument Panel Carrier Replacement.
32. Remove the HVAC. Refer to HVAC Module Assembly Replacement.
33. Remove the front seats. Refer to Front Seat Replacement - Bucket.
34. Remove the rear seat back. Refer to Rear Seat Back Replacement.
35. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
36. Remove the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
37. Remove the front seat belts. Refer to Front Seat Belt Replacement.
38. Remove the rear seat belts. Refer to Rear Seat Belt Replacement.
39. Remove the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
40. Remove the spare wheel and emergency kit from the rear compartment.
41. Remove the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
42. Remove the battery tray. Refer to Battery Tray Replacement.
43. Remove the positive cable from the vehicle. Refer to Battery Positive Cable Replacement.

Important: This step is unique to the sunroof.

44. Remove the sunroof module. Refer to Sunroof Module Assembly Replacement
45. Remove the roof. Refer to Roof Outer Replacement.
46. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



47. Remove the body side ring to upper dash panel body sealer (1)



48. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front wheelhouse assembly.
49. Remove the upper wheelhouse brace from the front wheelhouse assembly.



50. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



51. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



52. Locate, mark and drill out the factory welds (1) attaching the body side ring to the front hinge pillar.



53. Locate, mark and remove the factory seam welds (1) attaching the body side ring centre pillar to the inner rocker panel.



54. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the rear inner wheelhouse.



55. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the front hinge pillar.



56. Locate, mark and drill out the factory welds (1) attaching the body side ring to the vehicle.



57. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the parcel shelf assembly.



58. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the upper parcel shelf assembly.



59. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



60. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



61. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the rear end panel.
62. Remove the body side ring from the vehicle.



63. Remove the sealer (1) from the front plenum panel.
64. Remove the seam sealer (2) from the lower hinge pillar.



65. Remove the seam sealer (1) from the rear floor pan assembly.



66. Remove the seam sealer (1) from the inner side extension panel.



67. Remove the seam sealer (1) from the rear end panel.

Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Spot welding is the preferred method for attaching panels and should be used wherever possible. A plug weld should be performed where your spot welder is unable reach.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
2. Clean and prepare the mating surfaces of both parts of the body side ring.



3. Remove the unexpanded noise baffle (1) from the body side ring.



4. Apply structural adhesive GM6449G or equivalent 260 mm (10.24 in) (A) to the top edge of the inner hinge pillar.
5. Apply structural adhesive GM6449G or equivalent 400 mm (15.75 in) (B) to the inner rocker panel.



6. Apply structural adhesive GM6449G or equivalent 50 mm (1.97 in) (A) to the rear seat back on the forward facing surface.



7. Apply structural adhesive GM6449G or equivalent 110 mm (4.33 in) (A) to the parcel shelf.



8. Apply structural adhesive GM6449G or equivalent 40 mm (1.57 in) (A) to the body side centre roof bow.
9. Apply structural adhesive GM6449G or equivalent 60 mm (2.36  (B) to the body side front roof bow.



10. Apply the primary sealer (1) GM6449G or equivalent along the lower hinge pillar.



11. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the parcel shelf panel.
12. Position the body side on the vehicle. Verify correct alignment and position using three-dimensional measuring equipment.



13. Align the body side ring to the inner rocker flange tab (1).



14. Align the inner rear wheelhouse (1) to side extension panel (2).



15. Align the body side ring centre pillar to the indented flange (1) on the inner rocker panel.



16. Align the body side ring hinge pillar (2) to the wheelhouse assembly.
17. Align the body side ring hinge pillar (1) to the inner lower hinge pillar.



18. Seam weld the inner lower hinge pillar to inner upper hinge pillar 60 mm (2.36 in) (A) using a (Metal Inert Gas) MIG welder.



19. Seam weld the inner quarter panel to rear floor assembly 60 mm (2.36 in) (A) across the locating tag using a MIG welder.



20. Seam weld the centre pillar to inner rocker panel in two places 50 mm (1.97 in) (A) across the locating tags using a MIG welder.
21. Install the roof. Refer to Roof Outer Replacement.



22. Weld (1) the body side ring to the vehicle.



23. Weld (1) the body side ring to the front hinge pillar.



24. Weld (1) the body side ring assembly to the inner rear side extension panel.



25. Weld (1) the body side ring assembly to the inner rear wheelhouse.



26. Puddle weld (1) the body side ring assembly to the rear end panel.



27. Weld (1) the body side ring assembly to the upper parcel shelf assembly.



28. Weld (1) the body side ring assembly to the parcel shelf assembly.



29. Weld (1) the upper wheelhouse brace to the front hinge pillar.



30. Weld (1) the upper wheelhouse brace to the front hinge pillar.



31. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the upper wheelhouse brace.



32. Weld (1) the upper wheelhouse brace to the front wheelhouse assembly.



33. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the tail lamp and the quarter panel extension.



34. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the rear edge of the parcel shelf panel.



35. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the quarter panel extension.



36. Apply the secondary sealer (1)GM specification 9984532 or equivalent to the front plenum panel.
37. Apply the secondary sealer (2) GM specification 9984532 or equivalent to the lower hinge pillar.



38. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the inner rear wheelhouse assembly.



39. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



40. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



41. Apply expanding foam sealer GM9982296 or equivalent to the front lower hinge pillar through the access hole (1).



42. Apply expanding foam sealer GM9982296 or equivalent through the two access holes (1) in the rear wheelhouse assembly.




Important: This step is unique to the right body side ring.

43. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the fuel filler pocket.
44. Install the positive cable to the vehicle. Refer to Battery Positive Cable Replacement.
45. Install the battery tray. Refer to Battery Tray Replacement.
46. Install the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
47. Install the spare wheel and emergency kit from the rear compartment.
48. Install the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
49. Install the rear seat belts. Refer to Rear Seat Belt Replacement.
50. Install the front seat belts. Refer to Front Seat Belt Replacement.
51. Install the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
52. Install the rear seat back. Refer to Rear Seat Back Replacement.
53. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
54. Install the front seats. Refer to Front Seat Replacement - Bucket.
55. Install the HVAC. Refer to HVAC Module Assembly Replacement.
56. If re-programming is required. Refer to Control Module References.
57. Install the instrument panel. Refer to Instrument Panel Carrier Replacement.
58. If re-programming is required. Refer to Control Module References.
59. Install the brake master cylinder. Refer to Master Cylinder Replacement.
60. Install the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
61. If re-programming is required. Refer to Control Module References.
62. Install the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
63. Install the plenum chamber. Refer to Air Inlet Assembly Replacement.
64. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
65. Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
66. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
67. Install the fender assembly. Refer to Front Fender Replacement.
68. Install the front fascia. Refer to Front Bumper Fascia Replacement.
69. Install the rear fascia. Refer to Rear Bumper Fascia Replacement.
70. Install the brake lines. Refer to.
71. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
72. Install the front strut assembly. Refer to Strut Assembly Replacement.
73. Install the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
74. Install the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.

Important: This step is unique to the right body side ring.

75. Install the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.

Important: This step is unique to the right body side ring.

76. Install the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

77. Install the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

78. Install the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.
79. Install the rear frame assembly. Refer to Rear Frame Replacement.
80. Install the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
81. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
82. Lower the vehicle.
83. Install the front doors. Refer to Front Side Door Replacement.
84. Install the rear doors. Refer to Rear Door Replacement.
85. Install the positive cable to the engine bay. Refer to Battery Positive Cable Replacement.
86. Install the negative cable to the engine bay. Refer to Battery Negative Cable Replacement.
87. Install the engine assembly. Refer to Engine Replacement or Engine Replacement.
88. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
89. Enable the SIR system. Refer to SIR Disabling and Enabling.
90. If re-programming is required. Refer to Control Module References.