GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 Preface 🢒 Cautions and Notices 🢒 Body Lock Pillar Outer Panel 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.

    Important: This procedure was developed to allow full access for the replacement of the center reinforcement pillar replacement Center Reinforcement Pillar Replacement since sectioning is not endorsed or recommended to the reinforcement due to the ultra high strength steel.


    Object Number: 1985513 Size: SH
  1. The body side outer panel is available only in 1-piece side framer portions. You can perform any one of these replacement procedures separately or in any combination, depending upon the extent of the damage to the vehicle. Sectioning must take place in specified areas only.

    2. 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. Remove the sealers and anti-corrosion materials from the repair area, as necessary, and note their location. Refer to Anti-Corrosion Treatment and Repair .
  5. Repair as much of the damaged area as possible. Refer to Dimensions - Body .

    6. Object Number: 1985514 Size: SH
  6. Remove the weatherstrip, observe the flange in the center pillar area there will be a 3-metal stack-up. This will help to create an opening wide enough in the upper outer center pillar area to allow access to the reinforcement (A).

    7. Object Number: 1985515 Size: SH
  7. Measure the reinforcement size at the top of the center pillar (A) it should be approximately 14 inches in width. The opening to allow the removal of reinforcement (B) is approximately 15½ inches. This is the opening for the removal and is also the cut line.

    8. Object Number: 1985516 Size: SH
  8. From the door opening feature line (A) measure up 1½ inches this is the cut line. Using masking tape as guide follow the radius.

    9. Object Number: 1985518 Size: SH

    Important: Be careful not to cut into the Rocker Reinforcement.

  9. Cut in between the rocker molding holes.

    10. Object Number: 1985520 Size: SH
  10. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part.
  11. Remove the damaged center pillar.

Installation Procedure

    Object Number: 1985518 Size: SH
  1. From the service part cut the rocker in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of 1½ times the metal thickness at the sectioning joint.

    2. Object Number: 1985523 Size: SH
  2. On the top of the center outer pillar service part mark (A) and cut the 15½ inches wide that is corresponding to the remaining panel. The sectioning joint should be trimmed back to allow a gap 1½ times the metal thickness.

    3. Object Number: 1985525 Size: SH
  3. Measuring from the feature line (A) up 2¼ make marks and use masking tape to follow the contours. Make a cut, this is longer than the original cut to allow underlap.

    4. Object Number: 1985529 Size: SH
  4. From unused portion of service parts create 50 mm sleeves (A) leaving the sleeve shorter on the top 1/8  in to allow service panel underlap room.

    5. Object Number: 1218621 Size: SH
  5. In all the rocker panel areas, create a 100 mm (4 in) backing plate from the unused portion of the service part. Trim the backing plates as necessary to fit behind the sectioning joint.

    6. Object Number: 1985533 Size: SH
  6. Drill 8 mm (5/16 in) holes along the sectioning joints from the edge of the part and spaced 40 mm (1 in) apart.
  7. Drill 8 mm (5/16 in) plug weld holes in the service part, as necessary, in the corresponding locations noted on the original panel.
  8. Prepare all mating surfaces for welding, as necessary.
  9. Apply GM approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
  10. Fit the backing plates into the sectioning joints 50 mm (2 in) for the rocker section, for a total of 100 mm (4 in).
  11. Fit the backing plate in upper center pillar area 25 mm (1 in) into each side for a total of 50 mm (2 in).

    12. Object Number: 1985537 Size: SH
  12. Underlap (A) the service part to the original upper center pillar area.

    13. Object Number: 1985540 Size: SH
  13. Observe the underlap. It should be between the sleeve and the original panel (A).

    14. Object Number: 1985542 Size: SH
  14. Position the outer center pillar to the vehicle using 3-dimensional measuring equipment. Clamp the pillar in place.
  15. Plug weld accordingly.

    16. Object Number: 1836959 Size: SH
  16. To create a solid weld with minimum heat distortion, make a 25 mm (1 in) stitch weld along the seam with gaps of 25 mm (1 in) gaps between them. Go back and complete the stitch weld.
  17. Clean and prepare all of the welded surfaces.
  18. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair .
  19. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems .
  20. Install all of the related panels and components.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  22. Enable the SIR system. Refer to SIR Disabling and Enabling .