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.
Refer to
Outer Windshield Frame Pillar Sectioning
,
Rocker Outer Panel Sectioning
,
Body Lock Pillar Outer Panel Sectioning
and
Rear Pillar Sectioning
.
- Remove all of the related panels and components.
- Restore as much of the damage as possible to the factory specifications.
- Note the location and remove the following
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:
- 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 center 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 1½ 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
Outer Windshield Frame Pillar Sectioning
,
Rocker Outer Panel Sectioning
,
Body Lock Pillar Outer Panel Sectioning
and
Rear Pillar Sectioning
.
- Drill 8 mm (5/16 in) plug
weld holes along the sectioning cut on the remaining original part. Locate these holes
13 mm (1/2 in) from the edge and spaced 40 mm (1½ in)
apart.
Important: In any area damaged beyond recognition, space the plug weld holes every 40 mm
(1½ in) apart.
- Drill 8 mm (5/16 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.
- Position and align the center pillar to
the adjacent panels using the three-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 recommended products. Do not combine the paint systems. Refer
to the paint manufacturer's recommendation.
- Apply the following 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.