GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


Object Number: 749644  Size: SH

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 Door Frame Sectioning - Windshield Pillar Rocker Panel Sectioning Front Hinge Pillar Sectioning Rear Pillar Sectioning .


    Object Number: 749649  Size: SH
  1. Remove all of the related panels and components.
  2. Restore as much of the damage as possible to the factory specifications. Refer to Dimensions - Frame .

  3. Object Number: 749650  Size: SH
  4. Note the location and remove the following as necessary:
  5. • The sealers
    • The sound deadeners
    • The anti-corrosion materials

    Object Number: 749652  Size: SH

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

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

  7. Object Number: 749654  Size: SH
  8. Perform additional sectioning procedures. Refer to Outer Door Frame Sectioning - Windshield Pillar , Rocker Panel Sectioning , Front Hinge Pillar Sectioning and Rear Pillar Sectioning .

  9. Object Number: 749656  Size: SH
  10. Locate, and drill out all of the factory welds. Note the number and location of the welds for the installation of the service part.

  11. Object Number: 749658  Size: SH
  12. Remove the damaged center pillar section.

Installation Procedure


    Object Number: 749660  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 1/2 times the metal thickness at the sectioning joint.

  2. Object Number: 749663  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: 749664  Size: SH
  5. Perform additional sectioning procedures. Refer to Outer Door Frame Sectioning - Windshield Pillar , Rocker Panel Sectioning , Front Hinge Pillar Sectioning and Rear Pillar Sectioning .

  6. Object Number: 749668  Size: SH
  7. 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 (1-1/2 in) apart.

  8. Object Number: 749671  Size: SH

    Important: In any area damaged beyond recognition, space the plug weld holes every 40 mm (1-1/2 in) apart.

  9. 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.

  10. Object Number: 749673  Size: SH
  11. Prepare all of the attachment surfaces as necessary.
  12. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle.

  13. Object Number: 749675  Size: SH
  14. Position and align the center pillar to the adjacent panels using the three-dimensional measuring equipment.
  15. Plug weld accordingly.
  16. 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.

  17. Object Number: 749679  Size: SH
  18. Clean and prepare all of the welded surfaces.
  19. 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.

  20. Apply the following as necessary:
  21. • Apply the sound deadening materials.
    • Apply an approved anti-corrosion primer.
    • Apply the sealers and refinish as necessary.
  22. Install all of the related panels and components.