Side Door Opening Frame Replacement LWB

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

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

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

Caution: Refer to Battery Disconnect Caution in the Preface section.

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 the front doors. Refer to Front Side Door Replacement.
4. Remove the rear doors. Refer to Rear Door Replacement.
5. Remove the engine assembly. Refer to Engine Replacement or Engine Replacement.
6. Remove the negative cable from the engine bay. Refer to Battery Negative Cable Replacement.
7. Remove the positive cable from the engine bay. Refer to Battery Positive Cable Replacement.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Important: This step is unique to the right body side ring.

9. Remove the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.

Important: This step is unique to the right body side ring.

10. Remove the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

11. Remove the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.
12. Remove the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.
13. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
14. Remove the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
15. Remove the rear frame assembly. Refer to Rear Frame Replacement.
16. Remove the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.
17. Remove the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
18. Remove the front strut assembly. Refer to Strut Assembly Replacement.
19. Lower the vehicle.
20. Remove the brake lines. Refer to Brake Pipe Replacement.
21. Remove the fender assembly. Refer to Front Fender Replacement.
22. Remove the front fascia. Refer to Front Bumper Fascia Replacement.
23. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement.
24. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
25. Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
26. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
27. Remove the plenum chamber. Refer to Air Inlet Assembly Replacement.
28. Remove the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
29. Remove the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
30. Remove the brake master cylinder. Refer to Master Cylinder Replacement.
31. Remove the instrument panel. Refer to Instrument Panel Carrier Replacement.
32. Remove the HVAC. Refer to HVAC Module Assembly Replacement.
33. Remove the front seats. Refer to Front Seat Replacement - Bucket.
34. Remove the rear seat back. Refer to Rear Seat Back Replacement.
35. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
36. Remove the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
37. Remove the front seat belts. Refer to Front Seat Belt Replacement.
38. Remove the rear seat belts. Refer to Rear Seat Belt Replacement.
39. Remove the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
40. Remove the spare wheel and emergency kit from the rear compartment.
41. Remove the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
42. Remove the battery tray. Refer to Battery Tray Replacement.
43. Remove the positive cable from the vehicle. Refer to Battery Positive Cable Replacement.

Important: This step is unique to the sunroof.

44. Remove the sunroof module. Refer to Sunroof Module Assembly Replacement.
45. Remove the roof. Refer to Roof Outer Replacement.
46. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



47. Remove the body side ring to upper dash panel body sealer (1)



48. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front wheelhouse assembly.
49. Remove the upper wheelhouse brace from the front wheelhouse assembly.



50. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



51. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



52. Locate, mark and drill out the factory welds (1) attaching the body side ring to the front hinge pillar.



53. Locate, mark and remove the factory seam welds (1) attaching the body side ring centre pillar to the inner rocker panel.



54. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the rear inner wheelhouse.



55. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the front hinge pillar.



56. Locate, mark and drill out the factory welds (1) attaching the body side ring to the vehicle.



57. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the parcel shelf assembly.



58. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the upper parcel shelf assembly.



59. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



60. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



61. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the rear end panel.
62. Remove the body side ring from the vehicle.



63. Remove the sealer (1) from the front plenum panel.
64. Remove the seam sealer (2) from the lower hinge pillar.



65. Remove the seam sealer (1) from the rear floor pan assembly.



66. Remove the seam sealer (1) from the inner side extension panel.



67. Remove the seam sealer (1) from the rear end panel.

Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Spot welding is the preferred method for attaching panels and should be used wherever possible. A plug weld should be performed where your spot welder is unable reach.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
2. Clean and prepare the mating surfaces of both parts of the body side ring.



3. Remove the unexpanded noise baffle (1) from the body side ring.



4. Apply structural adhesive (1) GM6449G or equivalent 260 mm (10.24 in) (A) to the top edge of the inner hinge pillar.
5. Apply structural adhesive (1) GM6449G or equivalent 400 mm (15.75 in) (B) to the inner rocker panel.



6. Apply structural adhesive (1) GM6449G or equivalent 50 mm (1.97 in) (A) to the rear seat back on the forward facing surface.



7. Apply structural adhesive (1) GM6449G or equivalent 110 mm (4.33 in) (A) to the parcel shelf.



8. Apply structural adhesive (1) GM6449G or equivalent 40 mm (1.57 in) (A) to the body side centre roof bow.
9. Apply structural adhesive (1) GM6449G or equivalent 60 mm (2.36  (B) to the body side front roof bow.



10. Apply the primary sealer (1) GM6449G or equivalent along the lower hinge pillar.



11. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the parcel shelf panel.
12. Position the body side on the vehicle. Verify correct alignment and position using three-dimensional measuring equipment.



13. Align the body side ring to the inner rocker flange tab (1).



14. Align the inner rear wheelhouse (1) to side extension panel (2).



15. Align the body side ring centre pillar to the indented flange (1) on the inner rocker panel.



16. Align the body side ring hinge pillar (2) to the wheelhouse assembly.
17. Align the body side ring hinge pillar (1) to the inner lower hinge pillar.



18. Seam weld the inner lower hinge pillar to inner upper hinge pillar 60 mm (2.36 in) (A) using a (Metal Inert Gas) MIG welder.



19. Seam weld the inner quarter panel to rear floor assembly 60 mm (2.36 in) (A) across the locating tag using a MIG welder.



20. Seam weld the centre pillar to inner rocker panel in two places 50 mm (1.97 in) (A) across the locating tags using a MIG welder.
21. Install the roof. Refer to Roof Outer Replacement.



22. Weld (1) the body side ring to the vehicle.



23. Weld (1) the body side ring to the front hinge pillar.



24. Weld (1) the body side ring assembly to the inner rear side extension panel.



25. Weld (1) the body side ring assembly to the inner rear wheelhouse.



26. Weld (1) the body side ring assembly to the rear end panel.



27. Weld (1) the body side ring assembly to the upper parcel shelf assembly.



28. Weld (1) the body side ring assembly to the parcel shelf assembly.



29. Weld (1) the upper wheelhouse brace to the front hinge pillar.



30. Weld (1) the upper wheelhouse brace to the front hinge pillar.



31. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the upper wheelhouse brace.



32. Weld (1) the upper wheelhouse brace to the front wheelhouse assembly.



33. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the tail lamp and the quarter panel extension.



34. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the rear edge of the parcel shelf panel.



35. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the quarter panel extension.



36. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the front plenum panel.
37. Apply the secondary sealer (2) GM specification 9984532 or equivalent to the lower hinge pillar.



38. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the inner rear wheelhouse assembly.



39. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



40. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



41. Apply expanding foam sealer GM9982296 or equivalent to the front lower hinge pillar through the access hole (1).



42. Apply expanding foam sealer GM9982296 or equivalent through the two access holes (1) in the rear wheelhouse assembly.




Important: This step is unique to the right body side ring.

43. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the fuel filler pocket.
44. Install the positive cable to the vehicle. Refer to Battery Positive Cable Replacement
45. Install the battery tray. Refer to Battery Tray Replacement.
46. Install the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
47. Install the spare wheel and emergency kit from the rear compartment.
48. Install the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
49. Install the rear seat belts. Refer to Rear Seat Belt Replacement.
50. Install the front seat belts. Refer to Front Seat Belt Replacement.
51. Install the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
52. Install the rear seat back. Refer to Rear Seat Belt Replacement.
53. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
54. Install the front seats. Refer to Front Seat Replacement - Bucket.
55. Install the HVAC. Refer to HVAC Module Assembly Replacement.
56. Install the instrument panel. Refer to Instrument Panel Carrier Replacement.
57. Install the brake master cylinder. Refer to Master Cylinder Replacement.
58. Install the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
59. Install the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
60. Install the plenum chamber. Refer to Air Inlet Assembly Replacement.
61. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
62. Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
63. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
64. Install the fender assembly. Refer to Front Fender Replacement.
65. Install the front fascia. Refer to Front Bumper Fascia Replacement.
66. Install the rear fascia. Refer to Rear Bumper Fascia Replacement.
67. Install the brake lines. Refer to Brake Pipe Replacement.
68. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
69. Install the front strut assembly. Refer to Strut Assembly Replacement
70. Install the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
71. Install the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.

Important: This step is unique to the right body side ring.

72. Install the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.

Important: This step is unique to the right body side ring.

73. Install the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

74. Install the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

75. Install the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.
76. Install the rear frame assembly. Refer to Rear Frame Replacement.
77. Install the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
78. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
79. Lower the vehicle.
80. Install the front doors. Refer to Front Side Door Replacement.
81. Install the rear doors. Refer to Rear Door Replacement.
82. Install the positive cable to the engine bay. Refer to Battery Positive Cable Replacement.
83. Install the negative cable to the engine bay. Refer to Battery Negative Cable Replacement.
84. Install the engine assembly. Refer to Engine Replacement or Engine Replacement.
85. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
86. Enable the SIR system. Refer to SIR Disabling and Enabling.

Side Door Opening Frame Replacement SWB

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

Caution: Refer to Vehicle Lifting Caution in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

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

Caution: Refer to Battery Disconnect Caution in the Preface section.

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 the front doors. Refer to Front Side Door Replacement.
4. Remove the rear doors. Refer to Rear Door Replacement.
5. Remove the engine assembly. Refer to Engine Replacement or Engine Replacement.
6. Remove the negative cable from the engine bay. Refer to Battery Negative Cable Replacement.
7. Remove the positive cable from the engine bay. Refer to Battery Positive Cable Replacement.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Important: This step is unique to the right body side ring.

9. Remove the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.

Important: This step is unique to the right body side ring.

10. Remove the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

11. Remove the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.
12. Remove the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.
13. Remove the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
14. Remove the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
15. Remove the rear frame assembly. Refer to Rear Frame Replacement.
16. Remove the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.
17. Remove the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
18. Remove the front strut assembly. Refer to Strut Assembly Replacement.
19. Lower the vehicle.
20. Remove the brake lines. Refer to Brake Pipe Replacement.
21. Remove the fender assembly. Refer to Front Fender Replacement.
22. Remove the front fascia. Refer to Front Bumper Fascia Replacement.
23. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement.
24. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
25. Remove the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
26. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
27. Remove the plenum chamber. Refer to Air Inlet Assembly Replacement.
28. Remove the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
29. Remove the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
30. Remove the brake master cylinder. Refer to Master Cylinder Replacement.
31. Remove the instrument panel. Refer to Instrument Panel Carrier Replacement.
32. Remove the HVAC. Refer to HVAC Module Assembly Replacement.
33. Remove the front seats. Refer to Front Seat Replacement - Bucket.
34. Remove the rear seat back. Refer to Rear Seat Back Replacement.
35. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement.
36. Remove the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
37. Remove the front seat belts. Refer to Front Seat Belt Replacement.
38. Remove the rear seat belts. Refer to Rear Seat Belt Replacement.
39. Remove the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
40. Remove the spare wheel and emergency kit from the rear compartment.
41. Remove the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
42. Remove the battery tray. Refer to Battery Tray Replacement.
43. Remove the positive cable from the vehicle. Refer to Battery Positive Cable Replacement.

Important: This step is unique to the sunroof.

44. Remove the sunroof module. Refer to Sunroof Module Assembly Replacement
45. Remove the roof. Refer to Roof Outer Replacement.
46. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



47. Remove the body side ring to upper dash panel body sealer (1)



48. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front wheelhouse assembly.
49. Remove the upper wheelhouse brace from the front wheelhouse assembly.



50. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



51. Locate, mark and drill out the factory welds (1) attaching the upper wheelhouse brace to the front hinge pillar.



52. Locate, mark and drill out the factory welds (1) attaching the body side ring to the front hinge pillar.



53. Locate, mark and remove the factory seam welds (1) attaching the body side ring centre pillar to the inner rocker panel.



54. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the rear inner wheelhouse.



55. Locate, mark and remove the factory seam welds (1) attaching the body side ring to the front hinge pillar.



56. Locate, mark and drill out the factory welds (1) attaching the body side ring to the vehicle.



57. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the parcel shelf assembly.



58. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the upper parcel shelf assembly.



59. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



60. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the inner rear wheelhouse.



61. Locate, mark and drill out the factory welds (1) attaching the body side ring assembly to the rear end panel.
62. Remove the body side ring from the vehicle.



63. Remove the sealer (1) from the front plenum panel.
64. Remove the seam sealer (2) from the lower hinge pillar.



65. Remove the seam sealer (1) from the rear floor pan assembly.



66. Remove the seam sealer (1) from the inner side extension panel.



67. Remove the seam sealer (1) from the rear end panel.

Important: If the location of the original plug weld holes can not be determined, or if structural weld-thru adhesive is present, space the plug weld holes every 32 mm (1¼ in).

Important: Spot welding is the preferred method for attaching panels and should be used wherever possible. A plug weld should be performed where your spot welder is unable reach.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted from the original assembly.
2. Clean and prepare the mating surfaces of both parts of the body side ring.



3. Remove the unexpanded noise baffle (1) from the body side ring.



4. Apply structural adhesive GM6449G or equivalent 260 mm (10.24 in) (A) to the top edge of the inner hinge pillar.
5. Apply structural adhesive GM6449G or equivalent 400 mm (15.75 in) (B) to the inner rocker panel.



6. Apply structural adhesive GM6449G or equivalent 50 mm (1.97 in) (A) to the rear seat back on the forward facing surface.



7. Apply structural adhesive GM6449G or equivalent 110 mm (4.33 in) (A) to the parcel shelf.



8. Apply structural adhesive GM6449G or equivalent 40 mm (1.57 in) (A) to the body side centre roof bow.
9. Apply structural adhesive GM6449G or equivalent 60 mm (2.36  (B) to the body side front roof bow.



10. Apply the primary sealer (1) GM6449G or equivalent along the lower hinge pillar.



11. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the parcel shelf panel.
12. Position the body side on the vehicle. Verify correct alignment and position using three-dimensional measuring equipment.



13. Align the body side ring to the inner rocker flange tab (1).



14. Align the inner rear wheelhouse (1) to side extension panel (2).



15. Align the body side ring centre pillar to the indented flange (1) on the inner rocker panel.



16. Align the body side ring hinge pillar (2) to the wheelhouse assembly.
17. Align the body side ring hinge pillar (1) to the inner lower hinge pillar.



18. Seam weld the inner lower hinge pillar to inner upper hinge pillar 60 mm (2.36 in) (A) using a (Metal Inert Gas) MIG welder.



19. Seam weld the inner quarter panel to rear floor assembly 60 mm (2.36 in) (A) across the locating tag using a MIG welder.



20. Seam weld the centre pillar to inner rocker panel in two places 50 mm (1.97 in) (A) across the locating tags using a MIG welder.
21. Install the roof. Refer to Roof Outer Replacement.



22. Weld (1) the body side ring to the vehicle.



23. Weld (1) the body side ring to the front hinge pillar.



24. Weld (1) the body side ring assembly to the inner rear side extension panel.



25. Weld (1) the body side ring assembly to the inner rear wheelhouse.



26. Puddle weld (1) the body side ring assembly to the rear end panel.



27. Weld (1) the body side ring assembly to the upper parcel shelf assembly.



28. Weld (1) the body side ring assembly to the parcel shelf assembly.



29. Weld (1) the upper wheelhouse brace to the front hinge pillar.



30. Weld (1) the upper wheelhouse brace to the front hinge pillar.



31. Apply the primary sealer (1) GM6449G or equivalent along the rear edge of the upper wheelhouse brace.



32. Weld (1) the upper wheelhouse brace to the front wheelhouse assembly.



33. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the tail lamp and the quarter panel extension.



34. Apply the secondary sealer (1) GM specification 9984532 or equivalent along the rear edge of the parcel shelf panel.



35. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the quarter panel extension.



36. Apply the secondary sealer (1)GM specification 9984532 or equivalent to the front plenum panel.
37. Apply the secondary sealer (2) GM specification 9984532 or equivalent to the lower hinge pillar.



38. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the inner rear wheelhouse assembly.



39. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



40. Apply the secondary sealer (1) GM specification 9984532 or equivalent between the outer rear wheelhouse assembly and the inner rear wheelhouse assembly.



41. Apply expanding foam sealer GM9982296 or equivalent to the front lower hinge pillar through the access hole (1).



42. Apply expanding foam sealer GM9982296 or equivalent through the two access holes (1) in the rear wheelhouse assembly.




Important: This step is unique to the right body side ring.

43. Apply the secondary sealer (1) GM specification 9984532 or equivalent to the fuel filler pocket.
44. Install the positive cable to the vehicle. Refer to Battery Positive Cable Replacement.
45. Install the battery tray. Refer to Battery Tray Replacement.
46. Install the rear compartment floor carpet. Refer to Rear Compartment Floor Panel Carpet Replacement.
47. Install the spare wheel and emergency kit from the rear compartment.
48. Install the roof rail module. Refer to Inflatable Restraint Roof Side Rail Module Replacement - Front.
49. Install the rear seat belts. Refer to Rear Seat Belt Replacement.
50. Install the front seat belts. Refer to Front Seat Belt Replacement.
51. Install the rear window shelf trim. Refer to Rear Window Shelf Trim Panel Replacement.
52. Install the rear seat back. Refer to Rear Seat Back Replacement.
53. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement.
54. Install the front seats. Refer to Front Seat Replacement - Bucket.
55. Install the HVAC. Refer to HVAC Module Assembly Replacement.
56. If re-programming is required. Refer to Control Module References.
57. Install the instrument panel. Refer to Instrument Panel Carrier Replacement.
58. If re-programming is required. Refer to Control Module References.
59. Install the brake master cylinder. Refer to Master Cylinder Replacement.
60. Install the ABS unit. Refer to Brake Pressure Modulator Valve Assembly Replacement.
61. If re-programming is required. Refer to Control Module References.
62. Install the relay box. Refer to Underhood Electrical Center or Junction Block Replacement.
63. Install the plenum chamber. Refer to Air Inlet Assembly Replacement.
64. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement.
65. Install the front end module. Refer to Front End Panel Module Carrier Assembly Replacement.
66. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement.
67. Install the fender assembly. Refer to Front Fender Replacement.
68. Install the front fascia. Refer to Front Bumper Fascia Replacement.
69. Install the rear fascia. Refer to Rear Bumper Fascia Replacement.
70. Install the brake lines. Refer to.
71. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
72. Install the front strut assembly. Refer to Strut Assembly Replacement.
73. Install the front wheel hub assembly. Refer to Front Wheel Bearing and Hub Replacement.
74. Install the fuel tank. Refer to Fuel Tank Replacement or Fuel Tank Replacement.

Important: This step is unique to the right body side ring.

75. Install the fuel lines. Refer to Fuel Hose/Pipes Replacement - Chassis or Fuel Hose/Pipes Replacement - Chassis.

Important: This step is unique to the right body side ring.

76. Install the fuel filler actuator. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

77. Install the fuel filler door. Refer to Fuel Tank Filler Door Lock Actuator Replacement.

Important: This step is unique to the right body side ring.

78. Install the Filler Tube. Refer to Filler Tube Replacement or Filler Tube Replacement.
79. Install the rear frame assembly. Refer to Rear Frame Replacement.
80. Install the rear wheelhouse liner. Refer to Rear Inner Wheelhouse Replacement.
81. Install the front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
82. Lower the vehicle.
83. Install the front doors. Refer to Front Side Door Replacement.
84. Install the rear doors. Refer to Rear Door Replacement.
85. Install the positive cable to the engine bay. Refer to Battery Positive Cable Replacement.
86. Install the negative cable to the engine bay. Refer to Battery Negative Cable Replacement.
87. Install the engine assembly. Refer to Engine Replacement or Engine Replacement.
88. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
89. Enable the SIR system. Refer to SIR Disabling and Enabling.
90. If re-programming is required. Refer to Control Module References.