GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 749767  Size: SH

    Important: Section in the specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle.

  1. The door frame opening is a unique laser-weld design incorporating multiple metal thicknesses to ensure the structural integrity of the vehicle. The door frame can be replaced at factory seams, but requires the removal of the upper fender rail, the windshield, the roof panel and the quarter panel. The sectioning procedures have been developed as a more cost-effective alternative to complete the replacement. The specific area to be sectioned is determined by the extent of the damage to the vehicle.
  2. Determine which sections and panels need to be removed.


    Object Number: 749769  Size: SH
  3. Remove all of the related panels and components. Refer to the following procedures:
  4. •  Rocker Outer Panel Sectioning
    •  Center Pillar Sectioning
    •  Outer Windshield Frame Pillar Sectioning
    •  Body Lock Pillar Outer Panel Sectioning
  5. Restore as much of the damage as possible to the factory specifications.

  6. Object Number: 749770  Size: SH
  7. Note the location and remove the following materials, as necessary:
  8. • The sealers
    • The sound deadeners
    • The anti-corrosion materials

    Object Number: 749772  Size: SH

    Important: Do not damage any of the inner panels or the reinforcements.

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

  10. Object Number: 749773  Size: SH
  11. Perform additional sectioning procedures. Refer to the following procedures:
  12. •  Rocker Outer Panel Sectioning
    •  Center Pillar Sectioning
    •  Outer Windshield Frame Pillar Sectioning
    •  Body Lock Pillar Outer Panel Sectioning

    Object Number: 749775  Size: SH
  13. Locate, and drill out all of the factory welds. Note the number and location of the welds for the installation of the service part.

  14. Object Number: 749776  Size: SH
  15. Remove the damaged rear pillar section.

Installation Procedure


    Object Number: 749777  Size: SH
  1. Cut the replacement service part in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow 1.5 times the metal thickness at the sectioning joint.

  2. Object Number: 749778  Size: SH
  3. Create a 50-mm (2-in) (a) backing plate from the unused portion of the service part. Trim the backing plate as necessary to fit behind the sectioning joint.

  4. Object Number: 749780  Size: SH
  5. Perform additional sectioning procedures. Refer to the following procedures:
  6. •  Rocker Outer Panel Sectioning
    •  Center Pillar Sectioning
    •  Outer Windshield Frame Pillar Sectioning
    •  Body Lock Pillar Outer Panel Sectioning
  7. Drill 8 mm (0.3 in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (0.5 in) from the edge and spaced 40 mm (1.6 in) apart.

  8. Object Number: 749783  Size: SH

    Important: In any area with excess damage, space the plug weld holes every 40 mm (1.6 in) apart.

  9. Drill 8-mm (0.3-in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.

  10. Object Number: 749785  Size: SH
  11. Prepare all of the attachment surfaces as necessary.
  12. Apply the weld-thru primer to all of the bare metal surfaces.
  13. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle. Place welds 13 mm (0.5 in) (a) from the lower edge of the existing part.

  14. Object Number: 749787  Size: SH
  15. Position and align the rear lock pillar to the adjacent panels using the 3-dimensional measuring equipment.
  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. Then go back and complete the stitch weld.

  18. Object Number: 749788  Size: SH
  19. Clean and prepare all of the welded surfaces.
  20. Important: Prior to refinishing, refer to publication GM 4901M-2001 GM Approved Refinish Materials for the recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendations.

  21. Apply the following products, as necessary:
  22. • The sound deadening materials
    • An approved anti-corrosion primer
    • The sealers and refinish as necessary
  23. Install all of the related panels and components.