Removal Procedure
Important: Section
in the specified areas only. Sectioning outside of these areas may compromise the
structural integrity of the vehicle.
- 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.
Determine which sections and panels need to be removed.
- Remove all of the related panels and components.
Refer to the following procedures:
- Restore as much of the damage as possible to the factory specifications.
- Note the location and remove the following
materials, as necessary:
• | The anti-corrosion materials |
Important: Do not damage any of the inner panels or the reinforcements.
- Cut the panel where sectioning is to be performed.
- Perform additional sectioning procedures.
Refer to the following procedures:
- Locate, and drill out all of the factory welds. Note the number and location
of the welds for the installation of the service part.
- Remove the damaged rear pillar section.
Installation Procedure
- 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.
- 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.
- Perform additional sectioning procedures.
Refer to the following procedures:
- 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.
Important: In any area with excess damage, space the plug weld
holes every 40 mm (1.6 in) apart.
- 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.
- Prepare all of the attachment surfaces as
necessary.
- Apply the weld-thru primer to all of the bare metal surfaces.
- 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.
- Position and align the rear lock pillar
to the adjacent panels using the 3-dimensional measuring equipment.
- Plug weld accordingly.
- 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.
- Clean and prepare all of the welded surfaces.
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.
- Apply the following products, as necessary:
• | The sound deadening materials |
• | An approved anti-corrosion primer |
• | The sealers and refinish as necessary |
- Install all of the related panels and components.