For 1990-2009 cars

### Removal Procedure

Important: Sectioning must take place in specified areas only. Failure to do so may compromise the structural integrity of the vehicle.

1. Visually inspect and restore as much of the damage as possible to the factory specifications.
2. Remove all related panels and components. Refer to Windshield Replacement and Rear Window Replacement .
3. Remove the following as necessary:

• | Sealers

• | Sound deadeners

• | Anti-corrosion materials

• | Note placement and number of foam baffles for new installation. If baffles are damaged, replacement service parts are available.

4. Determine sectioning locations.
5. Mark a line and cut in approved sectioning areas.
6. Locate, mark and drill out all factory welds. Note the number and location of welds for installation of the service assembly.
7. Remove the damaged panel.

### Preparation of Service Part

1. Cut service part in corresponding locations to fit original cut lines.
2. Create 100 mm (4 in) backing plate (1) on rocker panel from unused portion of service part.
3. Create a 50 mm (2 in) backing plate (2) on upper quarter panel from unused portion of service part. Gap must equal one and one half times the thickness of the metal (3).

### Installation Procedure

1. Position the service part on vehicle. Check fit using body dimensions.
2. Temporarily remove service part to install GM P/N 12399117 Sealing Strip between outer wheelhouse and gas door pocket.
3. Weld backing plates into position.
4. Drill 8 mm (5/16 in) plug weld holes as noted from original locations. Also drill plug weld holes along the sectioned areas of the service part. These should be located 25 mm (1 in) from the edge of the cuts.
5. Prepare all mating surfaces for welding as necessary.
6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
7. Position service and clamp in place.
8. Stitch weld along entire sectioning joint. Make 25 mm (1 in) welds along the seam with 25 mm (1 in) gaps between them, then go back and complete the stitch weld. This will create a solid joint with minimal heat distortion.
9. Plug weld according to original locations.
10. Clean and prepare all welded surfaces.
11. Install the following as necessary:

• | Sealers

• | Sound deadeners

• | Anti-corrosion materials

• | Acoustic foam baffles as noted from original part

Important: Prior to refinishing, refer to the publication GM 4901M-D-2000 GM Approved Refinish Materials for recommended products. Do not combine paint systems. Refer to paint manufacturer's recommendations.

12. Apply 2-part catalyzed primer.
13. Refinish as necessary.
14. Install all related panels and components.