Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Important: 

1. Visually inspect and restore as much of the damage as possible to factory specifications.
2. Remove the windshield. Refer to Windshield Replacement in Stationary Windows.
3. Remove the front upper rail. Refer to Upper Rail Replacement .
4. Remove all related panels and components.
5. Position all wiring out of the way to prevent damage and for best access to vehicle.
6. Remove all sealers and anti-corrosion materials as necessary.



7. Select a cutting point on the hinge pillar approximately 100 mm (4 in) from the top of the windshield flange.



8. At the selected point (2), cut through the outer and reinforcement panels, leaving the inner panel intact.
9. Mark the inner panel (3) at points 50 mm (2 in) each side of the cut line on the outer panel and cut the inner panel at these two points (3).
10. Locate and mark all factory welds. Note the number and location of welds for installation of the service part.
11. Remove the 100 mm (4 in) section of the inner panel (1).



12. Cut through the rocker panel section of the door opening frame assembly. The cut point (1) should be through the third rocker panel molding attaching hole (2).
13. Cut through both the outer panel and the reinforcement.

Important: Note the location of the sound deadening foam for installation.

14. Drill out all factory welds as necessary.
15. Remove the damaged section of the outer hinge pillar.

1. On the service part , cut a replacement panel section (1), accurately measuring the position of cuts to match the section removed.



2. Remove a section of inner rocker panel (1). Cut 50 mm (2 in) each side of the cut in the rocker panel (2), this allows access for welding the rocker panel reinforcement.



3. Cut an existing length of surplus rocker panel section, to form a reinforcement (1), approximately 100 mm (4 in) in length.
4. Apply 3M Weld-Thru Coating P/N 05916, or equivalent, to all mating surfaces.
5. Clamp this reinforcement firmly behind the cut section of rocker panel on the vehicle and position plug welds at a maximum spacing of 35 mm (1.37 in) apart.



6. Cut an existing length of surplus reinforcement panel section (2), approximately 60 mm (2.36 in) in length, to fit on the inside of the outer panel of the replacement hinge pillar (3) at the point of the cut.
7. Remove the flanges from this reinforcement panel.
8. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
9. Drill 8 mm (5/16 mm) holes for plug welding in the service part in the locations noted from the original panel.
10. Clamp the reinforcement panel firmly behind the outer panel of the cut section of the hinge pillar and plug weld (1) in place.



11. Clamp the replacement panel in position on the vehicle and check the door opening dimensions. Refer to Dimensions - Body .



12. Plug weld (2) the top of the pillar to the manufactured reinforcement, then butt-weld (1) the two sections together.



13. Plug weld (2) the new panel in the rocker panel region, then butt-weld (1) the two sections together.



14. Gaining access through the removed section of inner panel, butt-weld (1) the reinforcement panels together.
15. Butt-weld the removed access panel (2) in position. Replace the plug welds with the same number that was removed.



16. Plug weld (1) the hinge pillar section along the door opening flange.
17. Plug weld (2) the flange beneath the rocker panel, attaching the new panel to the inner rocker panel.
18. Plug weld the remainder of the hinge pillar section accordingly.



19. Gaining access through the section of removed inner rocker panel, butt-weld (2) the new section of rocker panel reinforcement to the existing section.
20. Replace the removed section of inner rocker panel (1) by butt-welding it in place and plug welding it along the door opening flange.
21. Dress the butt-welds by grinding or sanding, ensuring sufficient material remains to guarantee the strength of the weld.
22. Install the door hinges. Refer to Front Side Door Hinge Replacement - Body Side in Doors.
23. Install the front upper rail. Refer to Upper Rail Replacement .

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.

24. Clean and prepare welded surfaces.

Important: It is necessary to apply the sound-deadening foam in the locations as noted from removal.

25. Prime with 2-part catalyzed primer.
26. Apply sealers and anti-corrosion materials as necessary.
27. Install the windshield. Refer to Windshield Replacement in Stationary Windows.
28. Install all related panels and components.