GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Malibu 🢒 Body 🢒 Collision Repair 🢒 Body Lock Pillar Outer Panel Reinforcement Sectioning

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.

  1. Disable the SIR system. Refer to SIR Disabling and Enabling in SIR.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  3. Remove all related panels and components.
  4. Repair as much of the damaged area as possible. Refer to Dimensions - Body .
  5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.

    6. Object Number: 1219530 Size: SH
  6. On the center pillar reinforcement, measure from the bottom of the top access hole (a) down 50 mm (2 in). Scribe a line.

    7. Object Number: 1305031 Size: SH
  7. Cut the panel at the mark made previously. At the same time, completely cut through the outer panel (1) and the inner reinforcements (2).

    8. Object Number: 1219541 Size: SH
  8. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.

    9. Object Number: 1219547 Size: SH
  9. Remove the damaged center pillar.

    10. Object Number: 1305032 Size: SH
  10. Drill out the 4 spot welds holding the remainder of the reinforcement still on the vehicle.

Installation Procedure

    Object Number: 1219530 Size: SH
  1. To prepare the service part, measure down from the bottom of the top access hole (a) 50 mm (2 in). Scribe a line on the center pillar reinforcement service part.

    2. Object Number: 1305109 Size: SH
  2. Before making the cut, drill the approximately 12 spot welds at the top of the service part. Separate the inner panel from he outer panel. This will allow you to make the cut without cutting into the backing reinforcements.

    3. Object Number: 1305130 Size: SH
  3. Use a flat-bladed tool to separate the inner reinforcement from the outer reinforcement.

    4. With the clearance made, the cut can be made without damage to the inner reinforcements.

  4. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the corresponding locations noted on the original panel.
  5. Prepare all mating surfaces for welding as necessary.
  6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.

    7. Object Number: 1305210 Size: SH
  7. Slide the top sectioning joint together by sliding the service part under the original part at the sectioning area.
  8. Position the service part on the vehicle using 3-dimensional measuring equipment. Clamp the part in place.

    9. Object Number: 1305241 Size: SH
  9. Plug weld accordingly.
  10. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the sectioning joint seam with gaps of 25 mm (1 in). Go back and complete the stitch weld.
  11. Clean and prepare all of the welded surfaces.
  12. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair in Paint and Coatings.
  13. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems in Paint and Coatings.
  14. Install all of the related panels and components.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  16. Enable the SIR system. Refer to SIR Disabling and Enabling in SIR.