For 1990-2009 cars

### Removal Procedure

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

Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section.

Warning: Refer to Collision Sectioning Warning in the Preface section.

Note: The door frame can be replaced at the factory seams, but requires the removal of the windshield, roof, and quarter panel. The sectioning procedures have been developed as a more cost-effective alternative to complete replacement. The specific area to be sectioned is determined by the extent of the damage to the vehicle.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove all related panels and components.
4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body.

Warning: Refer to Foam Sound Deadeners Warning in the Preface section.

5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
6. Perform additional sectioning procedures as necessary. Refer to Structure Identification.
7. Measure 70 mm (2 3/4 in) down from the lower fender bracket (1). Mark a horizontal line.

Note: Do not damage any inner panels or reinforcements.

8. Cut the panel in the locations where sectioning is to be performed.
9. Locate and drill out all factory welds. Note the number and location of the welds for installation of the service part.
10. Remove the damaged hinge pillar.
11. Cut and remove 30 mm (1 3/16 in) from the flanges on either side of the remaining section of the original pillar. Cut 5 mm (3/16 in) wide gaps in the bottom corners.
12. Step the tabs (1) inward to allow the door frame opening service section to fit over the original hinge pillar.

### Installation Procedure

1. On the service body side, measure 40 mm (1 9/16 in) down from the lower fender bracket. Mark a horizontal line. Cut the hinge pillar along this line.
2. Perform additional sectioning procedures as necessary to remove the unused areas of the service part.

Note: If the location of the original plug weld holes cannot be determined, or if structural weld-thru adhesive was present, space the plug weld holes every 40 mm (1 ½ in) apart.

3. 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.
4. Prepare all attachment surfaces, as necessary.
5. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair.
6. Position the hinge pillar to the vehicle using 3-dimensional measuring equipment. Clamp in place.
7. Plug weld accordingly.

Note: 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. Complete the stitch weld.

8. Clean and prepare all welded surfaces.
9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
10. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems.
11. Install all related panels and components.
12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
13. Enable the SIR system. Refer to SIR Disabling and Enabling.