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Installation Procedure

WARNING: This page is about a different car, the 2008 Saab 9-7X. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Cut Replacement Service Part (Rear Pillar)
    GM749777Courtesy of GENERAL MOTORS CORP.
  1. Cut the replacement service part in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow 1.5 times the metal thickness at the sectioning joint.
    2. Fig 2: Backing Plate Created From Unused Portion Of Service Part (Rear Pillar)
    GM749778Courtesy of GENERAL MOTORS CORP.
  2. Create a 50-mm (2-in) (a) backing plate from the unused portion of the service part. Trim the backing plate as necessary to fit behind the sectioning joint.
    3. Fig 3: Rocker Panel Sectioning, Pillar Sectioning (Center), Outer Door Frame Sectioning (Windshield Pillar), Hinge Pillar Sectioning (Front)
    GM749780Courtesy of GENERAL MOTORS CORP.
  3. Perform additional sectioning procedures. Refer to the following procedures:
  4. Drill 8 mm (0.3 in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (0.5 in) from the edge and spaced 40 mm (1.6 in) apart.
    5. Fig 4: Drilling Plug Weld Holes In Service Part (Rear Pillar)
    GM749783Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: In any area with excess damage, space the plug weld holes every 40 mm (1.6 in) apart.
  5. Drill 8-mm (0.3-in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.
    6. Fig 5: Fitting & Plug Weld Backing Plate To Vehicle
    GM749785Courtesy of GENERAL MOTORS CORP.
  6. Prepare all of the attachment surfaces as necessary.
  7. Apply the weld-thru primer to all of the bare metal surfaces.
  8. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle. Place welds 13 mm (0.5 in) (a) from the lower edge of the existing part.
    9. Fig 6: Aligning Rear Lock Pillar To Adjacent Panels
    GM749787Courtesy of GENERAL MOTORS CORP.
  9. Position and align the rear lock pillar to the adjacent panels using the 3-dimensional measuring equipment.
  10. Plug weld accordingly.
  11. 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. Then go back and complete the stitch weld.
    12. Fig 7: Welding Rear Pillar Panel To Vehicle
    GM749788Courtesy of GENERAL MOTORS CORP.
  12. Clean and prepare all of the welded surfaces.
    13. IMPORTANT: Prior to refinishing, refer to publication GM 4901M-2001 GM Approved Refinish Materials for the recommended products. Do not combine the paint systems. Refer to the paint manufacturer's recommendations.
  13. Apply the following products, as necessary:
    • The sound deadening materials
    • An approved anti-corrosion primer
    • The sealers and refinish as necessary
  14. Install all of the related panels and components.
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