GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 SL1/SC1/SW1 🢒 Body and Accessories 🢒 Collision Repair 🢒 Front Body Hinge Pillar Sectioning - 1/2 Section Replacement

    Object Number: 860930 Size: SH
  1. Note the amount and location of the spot welds.
  2. Remove the sealer and drill spot welds from:
    3. 2.1. The front body hinge pillar outer, below the section line.
    2.2. The rocker panel outer
    2.3. The rocker panel inner
    2.4. The front body hinge pillar inner
  3. Cut the service part along the marked line as per illustration. DO NOT damage the hinge pillar reinforcement. The line is measure from just below the wiring pass through downward, approximately 50 mm (2 in) wide per illustration.

    4. Important: Only cut the outer surface of the hinge pillar service part. The inner reinforcement is used as a backing plate when installing the new section.

  4. Perform any additional procedures as necessary to remove the unused areas of the service part.
  5. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original section.

    6. Important: To ensure a secure weld, the hinge pillar sectioning joint should have a gap of approximately one and a half times the thickness of the metal. Trim the parts as necessary to achieve this.

  6. Stitch weld along the entire hinge pillar sectioning joint. Make 25 mm (1 in) gaps between.
  7. Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
  8. Complete all of the other welds and sectioning procedures as necessary.
  9. Clean all of the weld seams with a wire brush, prime, and seal all repair areas.
  10. Apply a permanent underbody sealant.

    11. Important: Ensure that proper corrosion protection processes are used on all repair areas.

  11. Prime with a 2-part catalyzed primer.
  12. Apply sealers and corrosion protection materials according to the information in the Body Paint section of this service manual or the paint manufacturer's recommendations.
  13. Clean the surface for welding and grind the primer off of the new part at the connecting points. Apply 3M® Weld-Thru Coating P/N 05913, or equivalent, to all areas to be welded.
  14. Measure and align the front body hinge pillar sectioning 1/2 section. Clamp into place.
  15. Use a MIG to plug the weld.