Chevrolet 2002 User manual

2002 Avalanche 3-1

1

Door Frame

Sectioning

IMPORTANT: Section in specified areas

only. Sectioning outside of these areas

may compromise the structural integrity

of the vehicle. Do not section in laser

weld (1) areas of door frame sections.

The door frame opening is a unique

laser-weld design incorporating multiple

metal thicknesses to ensure the

structural integrity of the cab. The door

frame can be replaced at factory seams,

but requires the removal of the roof

panel, windshield and quarter panel.

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.

2002 Chevrolet Avalanche

3-2 2002 Avalanche

Windshield Pillar

Sectioning

Removal Procedure

1. Remove all related panels and

components.

2. Restore as much of the damage as

possible to factory specifications.

3. Note the location and remove the

following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Perform sectioning

in the windshield area 30␣ mm

(1-3/16␣ in.) above the third trim

mounting hole.

IMPORTANT: Take care not to

damage the inner panels or

reinforcements.

4. Cut the pillar in the locations where

sectioning is to be performed.

5. Locate and drill out all factory

welds. Note the number and

location of the welds for installation

of the service part.

6. Remove the damaged Windshield

Pillar section.

30 MM (1-3/16 IN)

50 MM (2 IN)

2002 Avalanche 3-3

Windshield Pillar

Sectioning

Installation Procedure

1. Cut the replacement pillar in

corresponding locations to fit the

remaining original panel. The

sectioning joint should be trimmed

to allow a gap of one and one-half

times the metal thickness at the

sectioning joint.

2. Create a 50␣ mm (2␣ in.) backing

plate from the unused portion of the

service part. Trim the backing plate

as necessary to fit behind the

sectioning joint.

3. Perform additional sectioning

procedures as necessary. Refer to

Center Pillar Sectioning; Front

Lower Pillar Sectioning; Rear Lock

Pillar Sectioning; and Rocker

Sectioning.

4. Drill 8␣ mm (5/16␣ in.) holes for plug

welding in the original part. Locate

these holes approximately 13␣ mm

(1/2␣ in.) from the edge of the

sectioning cuts and spaced 40␣ mm

(1-1/2␣ in.) apart.

5. Drill 8␣ mm (5/16␣ in.) plug weld

holes in the service panel as

necessary in the locations noted

from the original panel and along

the sectioning cut.

CAUTION: FOAM SEALERS ARE

FLAMMABLE AND SHOULD BE

REMOVED FROM ALL WELD

LOCATIONS.

6. Prepare the mating surfaces, as

necessary.

7. Apply weld-through primer to all

bare metal surfaces.

8. Fit the backing plate halfway into

the sectioning joint, clamp and plug

weld to the vehicle.

9. Align the Windshield Pillar to

adjacent panels using three-

dimensional measuring equipment.

10. Plug weld accordingly.

—continued

PLUG WELDS

13 MM

(1/2 IN)

ORIGINAL PART

BACKING PLATE

50 MM

(2 IN)

100 MM

(4 IN)

100MM

(4 IN)

BACKING PLATE

GAP = ONE AND ONE-HALF TIMES

THE THICKNESS OF THE METAL

3-4 2002 Avalanche

GAP =

ONE AND ONE-HALF TIMES

METAL THICKNESS

STITCH WELD

Windshield Pillar Sectioning

Installation Procedure con’t

11. 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. This

will create a solid joint with minimal

heat distortion.

12. Clean and prepare all welded

surfaces.

IMPORTANT: Prior to refinishing,

refer to the publication GM4901M-

D-01 GM Approved Refinish

Materials for recommended

products. Do not combine paint

systems. Refer to paint

manufacturer’s recommendations.

13. Apply an approved anti-corrosion

primer.

14. Apply sealers and refinish as

necessary.

15. Install all related panels and

components.

2002 Avalanche 3-5

Front Lower Hinge

Pillar Sectioning

Removal Procedure

1. Visually inspect and restore as much of

the damage as possible to factory

specifications.

2. Remove all related panels and

components.

3. Note the location and remove the

following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

4. Measure 80␣ mm (3-1/8 inches) down

from the large wiring harness hole in the

hinge pillar and mark a horizontal line.

5. Cut the pillar in the locations where

sectioning is to be performed.

IMPORTANT: Take care not to damage

the inner panel.

6. Locate, mark and drill out all necessary

factory welds. Note the number of welds

for the installation of the service section.

7. Remove the damaged section of the door

frame opening.

IMPORTANT: The metal of the hinge

pillar is of a heavy gauge. However, the

tabs can be created using the appropriate

tools.

8. Cut and remove 30␣ mm (1-3/16 inches)

from the flanges on either side of the

remaining section of the original hinge

pillar to create 30␣ mm (1-3/16␣ in.) tabs.

Cut 5␣ mm (3/16␣ in.) wide gaps in the

bottom corners.

9. Step the tabs inward to allow the door

frame opening service section to fit over

the original hinge pillar. Weld the tabs

together along the edges.

80 MM (3-1/8 IN)

ORIGINAL

PANEL

30 MM (1-3/16 IN)

5 MM (3/16 IN)

WELD TOGETHER

3-6 2002 Avalanche

Front Lower Hinge

Pillar Sectioning

Installation Procedure

1. On the service part, measure 50␣ mm (2␣ in.)

down from the large wiring harness hole in

the hinge pillar and 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. Refer to Windshield

Sectioning; Center Pillar, Rear Lock Pillar,

and Rocker Sectioning.

NOTICE: In any area damaged beyond

recognition, space plug weld holes every

40␣ mm (1-1/2␣ in.) apart.

3. Drill 8␣ mm (5/16␣ in.) plug weld holes as

necessary in the locations noted from the

original section. Also drill plug weld holes

along the hinge pillar sectioning cut of the

service part. These should be located

approximately 15␣ mm (9/16␣ in.) from the

edge of the cut.

CAUTION: FOAM SEALERS ARE

FLAMMABLE AND SHOULD BE

REMOVED FROM ALL WELD

LOCATIONS.

4. Prepare mating surfaces as necessary.

5. Apply weld-thru primer to all bare-metal

surfaces.

6. Position the service section over the

stepped tab on the original hinge pillar,

allowing 30␣ mm (1-3/16 inches) of overlap.

Check fit using three-dimensional

measuring.

7. Plug weld service part in position.

8. Make 25␣ mm (1␣ in.) welds along the seam

with 25␣ mm (1␣ in.) gaps between. Then go

back and complete the stitch weld. This

will create a solid joint with minimal heat

distortion.

9. Clean and prepare all welded surfaces.

IMPORTANT: Prior to refinishing,

refer to the publication GM4901M-D-01

GM Approved Refinish Materials for

recommended products. Do not combine

paint systems. Refer to paint manufacturer’s

recommendations.

10. Apply an approved anti-corrosion primer.

11. Apply sealers and refinish as necessary.

12. Install all related panels and components.

50 MM (2 IN)

SERVICE

PANEL

ORIGINAL

PANEL

NEW

SERVICE PANEL

ORIGINAL

PANEL

30 MM (1-3/16 IN)

OF OVERLAP

2002 Avalanche 3-7

Center Pillar

Sectioning

Removal Procedure

1. Remove all related panels and

components.

2. Restore as much of the damage as

possible to factory specifications.

3. Note the location and remove the

following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Take care not to

damage the inner panels or

reinforcements.

4. Cut the Center Pillar in the location

where sectioning is to be performed.

5. Locate and drill out all factory

welds. Note the number and

location of the welds for installation

of the service part.

6. Remove the damaged Center Pillar

section.

1

3-8 2002 Avalanche

Center Pillar

Sectioning

Installation Procedure

1. Cut the replacement Center Pillar in

corresponding locations to fit the

remaining original panel. The sectioning

joint should be trimmed to allow a gap of

one-and-one-half times the metal

thickness at the sectioning joint.

2. Create a 50␣ mm (2␣ in.) backing plate

from the unused portion of the service

part. Trim the backing plate as necessary

to fit behind the sectioning joint.

3. Perform additional sectioning procedures

as necessary. Refer to Windshield

Sectioning; Front Lower Pillar

Sectioning; Rear Lock Pillar Sectioning;

and Rocker Sectioning.

4. Drill 8␣ mm (5/16␣ in.) plug weld holes

along the sectioning cut on the

remaining original part.

5. Drill 8␣ mm (5/16␣ in.) plug weld holes in

the service panel as necessary in the

locations noted from the original panel

and along the sectioning cut.

CAUTION: FOAM SEALERS ARE

FLA␣ MMABLE AND SHOULD BE

REMOVED FROM ALL WELD

LOCATIONS.

6. Prepare the mating surfaces as necessary.

7. Apply weld-through primer to all bare

metal surfaces.

8. Fit the backing plate halfway into the

sectioning joint, clamp and plug weld to

the vehicle.

—continued

1

50MM

(2 IN)

100MM

(4 IN)

PLUG WELDS

13 MM

(1/2 IN)

ORIGINAL PART

BACKING PLATE

2002 Avalanche 3-9

GAP =

ONE AND ONE-HALF TIMES

METAL THICKNESS

STITCH WELD

Center Pillar Sectioning

Installation Procedure con’t

9. Align the Center Pillar to adjacent

panels using three-dimensional

measuring equipment.

10. Plug weld accordingly.

11. 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. This

will create a solid joint with minimal

heat distortion.

12. Clean and prepare all welded

surfaces.

IMPORTANT: Prior to refinishing,

refer to the publication GM4901M-

D-01 GM Approved Refinish

Materials for recommended

products. Do not combine paint

systems. Refer to paint

manufacturer’s recommendations.

13. Apply an approved anti-corrosion

primer.

14. Apply sealers and refinish as

necessary.

15. Install all related panels and

components.

3-10 2002 Avalanche

Rear Lock Pillar

Sectioning

Removal Procedure

1. Remove all related panels and components.

2. Restore as much of the damage as possible to

factory specifications.

3. Note the location and remove the following

as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Take care not to damage the

inner panels or reinforcements.

4. Cut the Rear Lock Pillar in the locations

where sectioning is to be performed.

5. Locate and drill out all factory welds. Note

the number and location of the welds for

installation of the service part.

6. Remove the damaged Rear Lock Pillar

section.

1

2002 Avalanche 3-11

Rear Lock Pillar

Sectioning

Installation Procedure

1. Cut the replacement Rear Lock

Pillar in corresponding locations to

fit the remaining original panel. The

sectioning joint should be trimmed

to allow a gap of one-and-one-half

times the metal thickness at the

sectioning joint.

2. Create a 50␣ mm (2␣ in.) backing

plate from the unused portion of the

service part. Trim the backing plate

as necessary to fit behind the

sectioning joint.

3. Perform additional sectioning

procedures as necessary. Refer to

Windshield Sectioning; Front Lower

Pillar Sectioning; Center Pillar; and

Rocker Sectioning.

4. Drill 8 ␣ mm (5/16␣ in.) plug weld

holes along the sectioning cut on

the remaining original part.

5. Drill 8␣ mm (5/16␣ in.) plug weld

holes in the service panel as

necessary in the locations noted

from the original panel and along

the sectioning cut.

CAUTION: FOAM SEALERS ARE

FLAMMABLE AND SHOULD BE

REMOVED FROM ALL WELD

LOCATIONS.

6. Prepare the mating surfaces, as

necessary.

7. Apply weld-through primer to all

bare metal surfaces.

8. Fit the backing plate halfway into

the sectioning joint, clamp and plug

weld to the vehicle.

BACKING PLATE

50 MM

(2 IN)

100 MM

(4 IN)

PLUG WELDS

13 MM

(1/2 IN)

ORIGINAL PANEL

BACKING PLATE

3-12 2002 Avalanche

GAP =

ONE AND ONE-HALF TIMES

THE METAL THICKNESS

STITCH WELD

Rear Lock Pillar Sectioning

Installation Procedure con’t

9. Align the Rear Lock Pillar to

adjacent panels using three-

dimensional measuring equipment.

10. Plug weld accordingly.

11. 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. This

will create a solid joint with minimal

heat distortion.

12. Clean and prepare all welded

surfaces.

IMPORTANT: Prior to refinishing,

refer to the publication GM4901M-

D-01 GM Approved Refinish

Materials for recommended

products. Do not combine paint

systems. Refer to paint

manufacturer’s recommendations.

13. Apply an approved anti-corrosion

primer.

14. Apply sealers and refinish as

necessary.

15. Install all related panels and

components.

2002 Avalanche 3-13

Rocker Panel

Sectioning

Removal Procedure

1. Remove all related panels and

components.

2. Restore as much of the damage as

possible to factory specifications.

3. Note the location and remove the

following as necessary:

• Sealers

• Sound deadeners

• Anti-corrosion materials

IMPORTANT: Take care not to

damage the inner panels or

reinforcements.

4. Cut the Rocker Panel in the

locations where sectioning is to be

performed.

5. Locate and drill out all factory

welds. Note the number and

location of the welds for installation

of the service part.

6. Remove the damaged Rocker Panel

section.

1

3-14 2002 Avalanche

Rocker Panel

Sectioning

Installation Procedure

1. Cut the replacement Rocker Panel in

corresponding locations to fit the

remaining original panel. The sectioning

joint should be trimmed to allow a gap of

one-and-one-half times the metal thickness

at the sectioning joint.

2. Create a 100␣ mm (4␣ in.) backing plate

from the unused portion of the service

part. Trim the backing plate as necessary

to fit behind the sectioning joint.

3. Perform additional sectioning procedures

as necessary. Refer to Windshield

Sectioning; Front Lower Pillar Sectioning;

Rear Lock Pillar Sectioning; and Center

Pillar sectioning.

4. Drill 8␣ mm (5/16␣ in.) plug weld holes along

the sectioning cut on the remaining

original part.

5. Drill 8␣ mm (5/16␣ in.) plug weld holes in

the service panel as necessary in the

locations noted from the original panel and

along the sectioning cut.

CAUTION: FOAM SEALERS ARE

FLAMMABLE AND SHOULD BE

REMOVED FROM ALL WELD

LOCATIONS.

6. Prepare the mating surfaces as necessary.

7. Apply weld-through primer to all bare

metal surfaces.

8. Fit the backing plate halfway into the

sectioning joint, clamp and plug weld to

the vehicle.

9. Align the Rocker Panel to adjacent panels

using three-dimensional measuring

equipment.

10. Plug weld service part in position.

11. 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. This will create a solid joint

with minimal heat distortion.

12. Clean and prepare all welded surfaces.

IMPORTANT: Prior to refinishing, refer to

the publication GM4901M-D-2000 “GM

Approved Refinish Materials” for

recommended products. Do not combine

paint systems. Refer to paint manufacturer’s

recommendations.

13. Apply an approved anti-corrosion primer.

14. Apply sealers and refinish as necessary.

15. Install all related panels and components.

100 MM

(4 IN)

BACKING PLATE

GAP = ONE AND ONE-HALF TIMES

THE THICKNESS OF THE METAL

2002 Avalanche 3-15

HINGE

PILLAR

13 MM (1/2 IN)

ROTABROACH BIT

HINGE REINFORCEMENT

TYPICAL MIG WELD

DRILL THROUGH HINGE ONLY

Front Body-Side

Hinge Replacement

Removal Procedure

1. Remove related panels and

component.

2. Remove any excess sealer

surrounding the existing hinge and

scribe the location of the hinge on

the hinge pillar.

3. Lightly hand-sand the existing hinge

with 100 grit or finer sandpaper in

order to locate the

4 welds that attach the hinge to the

pillar.

IMPORTANT: Punch the center of

the weld so that as much of the weld

as possible is removed during the

drilling.

4. Center punch each of the four weld

marks on the original hinge.

IMPORTANT: Do not drill into the

hinge pillar.

5. Drill through the hinge only, at each

punch location. Use a 13␣ mm (1/

2␣ in.) rotabroach hole saw or

equivalent.

6. Remove the hinge. If necessary, use

a chisel in order to separate the

hinge from the pillar.

7. Remove all of the remaining weld

from the pillar surface in order to

ensure a flush fit of the service

hinge.

3-16 2002 Avalanche

Front Body-Side

Hinge Replacement

Installation Procedure

1. Repair any damage done to the pillar

during the drilling or the removal.

2. Position the service hinge within the

scribe marks on the pillar.

3. Center punch each stud location on

the hinge pillar according to the

service hinge.

4. Drill a 3 ␣ mm (1/8␣ in.) pilot hole at

each center punch location.

IMPORTANT: Drill must be exact size.

5. Drill an 11.5 mm (29/64␣ in.) hole at

the pilot locations for the studs.

IMPORTANT: Prior to refinishing,

refer to the publication GM4901M-D-

2000 “GM Approved Refinish

Materials” for recommended products.

Do not combine paint systems. Refer to

paint manufacturer’s

recommendations.

6. Clean and prepare all of the bare

metal surfaces.

7. Apply an approved anti-corrosion

primer.

8. Feed fish wire, GM P/N 15017229 or

the equivalent, through the hinge, the

hinge stud hole and out of the

conduit hole in the pillar.

9. Install the stud, GM P/N 15017230,

supplied with the service hinge into

the wire end. Pull the stud into

position.

10. Hold the stud in position with the

hinge and remove the fish wire.

11. Draw the stud tight through the

pillar. Use the nuts (GM P/N

11516746) supplied.

12. Repeat steps 7-10 on the remaining

stud locations.

13. Remove each service nut.

14. Apply a full-bodied caulk to the entire

hinge mounting surface in order to

ensure a proper seal.

3 MM (1/8 IN)

PILOT

11.5 MM (29/64 IN)

DRILL

2002 Avalanche 3-17

Hinge

Nuts

Pillar

Hinge

Reinforcement

Studs

Front Body-Side Hinge

Replacement

Installation Procedure con’t

15. Install the hinge to the pillar. Use

the supplied nuts.

16. Torque the hinge to the pillar nuts

to 25␣ ␣ N·m (18 ft lb.).

17. Clean and prepare all of the

surfaces as necessary for refinishing.

18. Apply the sealers. Refinish the

surfaces as necessary.

19. Install and align all of the related

panels and the components.

3-18 2002 Avalanche

Front Door-Side

Hinge Replacement

Removal Procedure

1. Remove related panels and

components.

2. Remove any excess sealer surrounding

the hinge and scribe the location of

the hinge on the door.

3. Lightly hand-sand the existing body

hinge with 100 grit or finer sandpaper

in order to locate the 4 welds that

attach the hinge to the door.

IMPORTANT: Punch the center of the

weld so that as much of the weld is

removed during the drilling as possible.

4. Center punch each of the four weld

marks on the original hinge base.

IMPORTANT: Do not drill into the

door.

5. Drill through hinge base only at the

punch location. Use a 13 mm (1/2␣ in.)

rotabroach hole saw, or the equivalent.

6. Remove hinge. If necessary, use a

chisel to separate the hinge from the

door.

7. Remove all of the remaining weld from

the door surface in order to ensure a

flush fit of the service hinge.

13mm (1/2 inch)

Rotabroach Bit

Hinge

Door

Hinge Reinforcement

Typical Mig Weld

Drill through hinge only

2002 Avalanche 3-19

Front Door-Side

Hinge Replacement

Installation Procedure

1. Repair any damage done to door

during the drilling or the removal.

2. Clean and prepare the backing plate

mounting surfaces in order to

ensure a flush fit of the backing

plate.

3. Position the service hinge within the

scribe marks on the door.

4. Center punch each hole location on

the door according to the service

hinge.

5. Drill a 3 mm (1/8␣ in.) pilot hole at

each center punch location.

6. Drill a 13 mm (1/2␣ in.) hole at the

pilot locations.

IMPORTANT: Prior to refinishing,

refer to the publication GM4901M-

D-2000 “GM Approved Refinish

Materials” for recommended

products. Do not combine paint

systems. Refer to paint

manufacturer’s recommendations.

7. Clean and prepare all of the bare

metal surfaces.

8. Apply an approved anti-corrosion

primer.

9. Apply full-bodied caulk to the entire

hinge mounting surface in order to

ensure a proper seal.

10. Align the hinge and the backing

plate with the holes in the door

(Fig. 4-34).

11. Install the bolts. Tighten the bolts

to 25 ␣ N·m (18 ft lb).

12. Apply the sealers.

13. Refinish the metal surfaces as

necessary.

14. Install and align all of the related

panels and the components.

3 MM (1/8 IN)

PILOT

13 MM (1/2 IN)

DRILL

HINGE

DOOR

BOLTS

BACKING

PLATE

3-20 2002 Avalanche

Rear Body-Side

Hinge Replacement

Removal Procedure

1. Remove related panels and

components.

2. Remove any excess sealer

surrounding the existing hinge and

scribe the location of the hinge on

the hinge pillar.

3. Lightly hand-sand the existing hinge

with 100 grit or finer sandpaper in

order to locate the

4 welds that attach the hinge to the

pillar.

IMPORTANT: Punch the center of

the weld so that as much of the weld

as possible is removed during the

drilling.

4. Center punch each of the 4 weld

marks on the original hinge.

IMPORTANT: Do not drill into the

hinge pillar.

5. Drill through the hinge only at each

punch location. Use a 13␣ mm

(1/2␣ in.) rotabroach hole saw or the

equivalent.

6. Remove the hinge. If necessary, use

a chisel in order to separate the

hinge from the pillar.

7. Remove all of the remaining weld

from the pillar surface in order to

ensure a flush fit of the service

hinge.

HINGE

PILLAR

13 MM (1/2 IN)

ROTABROACH BIT

HINGE REINFORCEMENT

TYPICAL MIG WELD

DRILL THROUGH HINGE ONLY

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Chevrolet 2002 User manual

Chevrolet 2002 User manual

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