Important: Use due care not to cut adjacent panels when cutting the inner reinforcements.

1. Remove all related panels and components including the front door.
2. Position all wiring out of the way to prevent damage.
3. Visually inspect and restore as much of the damage as possible to factory specifications.
4. Remove sealers and anti-corrosion materials as necessary.



5. On the original reinforcement panels (1) measure 120 mm (4 3/4 in) down from the large wiring harness hole in the hinge pillar and mark a horizontal line.
6. Cut the inner reinforcement along this line.
7. Locate, mark, and drill out all factory welds, as necessary. Note the number and location of welds for installation of the service part.
8. Remove the damaged section of the inner reinforcement (2).

1. Cut and remove 30 mm (1 3/16 in) from the flanges on either side of the remaining section of the original hinge pillar to create 30 mm (1 3/16 in) flange.
2. Cut 5 mm (3/16 in) wide gaps in the bottom corners.



3. Step the tabs inward to allow the door frame inner reinforcement service section to fit over the original inner reinforcement.
4. Weld the tabs together along the edges (1).



5. On the service part (1) measure 90 mm (3 1/2 in) down from the large wiring harness hole in the hinge pillar and mark a horizontal line.
6. Cut the hinge pillar along this line.



7. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original panel.
8. Also drill plug weld holes along the sectioning cut of the service part (2). These should be located approximately 15 mm ( 9/16 in) from the edge of the cut.
9. Prepare mating surfaces and position the service section (2) over the stepped tab on the original inner reinforcement (1) allowing 30 mm (1 3/16 in) of overlap.
10. Check and make sure the door hinge bolt holes are properly located.
11. Plug weld accordingly.



12. Stitch weld along the entire joint (1).
13. Make 25 mm (1 in) gaps between.
14. Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
15. Clean and prepare welded surfaces.

Important: Prior to refinishing, refer to GM P/N 4901MD-99 Refinish Manual for recommended products.

16. Prime with 2-part catalyzed primer.
17. Apply sealers and anti-corrosion materials as necessary.
18. Install all related panels and components.