For 1990-2009 cars only
Removal Procedure
- Visually inspect and restore as much of the damage as possible to factory specifications.
- Remove all related panels and components.
- Position all wiring out of the way to prevent damage.
- Remove sealers and anti-corrosion materials as necessary.
- On the original outer door frame (2) measure down from the lower edge (1) of the door opening 200 mm (8 in) and mark a horizontal line.
- Cut the outer door frame along this line for sectioning. Do not cut into the inner reinforcement.
- Locate and mark all factory welds. Note the number and location of welds for installation of the service section.
- Drill out all factory welds as necessary.
- Perform additional sectioning procedures as necessary to remove the center lock pillar.
- Remove the damaged section of the door frame opening (4).
Installation Procedure
- On the service part (4), mark a horizontal line to leave a gap of 1½ times the thickness of the metal (5) at the sectioning joint.
- Cut the service panel along this line.
- Drill 8 mm (5/16 in) holes for plug welding in the service part (4) in the locations noted from the original panel.
- Drill holes for plug welding long the sectioning cuts on the services part.
- Locate these holes approximately 13 mm (17/32 in) from the edge of the sectioning cuts.
- Prepare the mating surfaces and position the service part using three-dimensional measuring equipment.
- Plug weld accordingly.
- Use the inner reinforcement (3) as a backing plate and stitch weld along the entire sectioning joint.
- Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between.
- Go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
- Complete all other welds and sectioning procedures as necessary.
- Clean and prepare welded surfaces.
- Prime with 2-part catalyzed primer.
- Apply sealers and anti-corrosion materials as necessary.
- Install all related panels and components.
Important: Prior to refinishing, refer to GM 4901MD-99 Refinish Manual for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.
